BAKER DD7 INSTALLATION INSTRUCTIONS
Contents
1. In the event warranty service is required the original purchaser must call or write BAKER immediately with the problem If it is deemed necessary for BAKER to make an evaluation to determine whether the transmission assembly or transmission kit is defective the entire transmission assembly whether originally purchased as an assembly or kit must be properly packaged and returned prepaid to BAKER with a copy of the original invoice of purchase If after an evaluation has been made by BAKER and a defect in materials and or workmanship is found BAKER will at BAKER s option repair or replace the defective part of the assembly Warranty card must be returned within 45 days of purchase to be valid ADDITIONAL WARRANTY PROVISIONS This limited warranty does not cover labor or other costs or expenses incidental to the repair and or replacement of BAKER products This warranty does not apply if one or more of the following situations is judged by BAKER to be relevant improper installation accident modification including but not limited to use of unauthorized parts racing high performance application mishandling misapplication neglect including but not limited to improper maintenance or improper repair BAKER shall not be liable for any consequential or incidental damages arising out of or in connection with a BAKER transmission assembly transmission kit swingarm fender component or part Consequential damages2. Remove the new 7th Main Drive Gear pn DD7 7M from the DD7 Gearset by simply sliding it off of the mainshaft Lube the snout of the Main Drive gear and the O ring already on the gear with WD 40 or equivalent to aid in assembly Following the Factory Service Manual press the gear into place and install the provided Main Drive Gear Seal pn 12074 4 Hang the provided Bearing Door Gasket pn 35645 06 on the inside of the bearing door Apply some WD 40 or equivalent to the main drive gear seal and the mainshaft on the portion adjacent to the clutch splines to aid in gearset installation Holding the gasket place over the 10 mm hollow dowels on the backside of the bearing door slide the entire gearset into the transmission case Be sure that the threads of the mainshaft do not contact the seal in the main drive gear If the shaft tears the seal leakage will occur It may take some jiggling of the gearset to get the fork rods to line up with the Teflon lined bushings in the case but the gearset should slide all the way into the transmission case until the gasket is flat against the door surface The fork rods are designed to have a tight slip fit into their bores on the bearing door If you find the forks rods try to slip out of place while sliding the gearset into the case remove the gearset and apply some thick grease to ends of the fork rods and push them back into the door This will help to hold them in place while you are sliding the gears
3. Remember to disconnect the two O2 sensor plugs from the pipes so as to not damage them when pulling the pipes off Unbolt the starter pull it out and set aside on your workbench Pull off the outer primary the primary chain clutch assembly and the inner primary Having a drip pan underneath the primary when you are taking off the outer primary is a great idea as residual oil will get all over your lift or garage floor depending on your work environment Pull the bearing race found on the mainshaft next with your Inner Race Service tool You can not pull the gearset out of the case without first removing this bearing race Remove the transmission pulley and set aside at this point as well NOTE Pulley nuts are Right Hand threads 3 Remove the bolts on the side cover remove it and set aside for reuse as it will bolt back up to the DD7 Bearing Door You do not need to disconnect it from the Clutch Cable Remove the Neutral Switch and Vehicle Speed Sensor from the top of the transmission case Having the sensor and switch removed makes installation of the new DD7 Gearset cassette easier REMOVE THE TRANSMISSION DIPSTICK AT THIS TIME YOU CAN NOT PULL THE al GEARSET WITH THE DIPSTICK IN THE BIKE IT WILL BREAK OFF IF YOU LEAVE IT IN THE BIKE WHEN ATTEMPTING TO PULL THE GEARSET 4 Remove the top cover and set aside this is necessary so that you can pull the shifter pawl off of the drum when you remove the entire gearset and trap door assembly A
4. shall include without limitation loss of use income or profit or losses sustained as the result of injury including death to any person or loss of or damage to property BAKER transmissions transmission kits and Wide Tire Kits are designed exclusively for use in Harley Davidson motorcycles BAKER shall have no warranty or liability obligation if a BAKER part is used in any other application If it is determined that a BAKER transmission assembly has been disassembled during the warranty period for any reason this limited warranty will no longer apply PAGE 11 TERMS v 11 041015 The words Harley and H D are registered trademarks and are for reference only Use of H D model designations and part numbers are for reference only BAKER Drivetrain has no association with and makes no claim against these words trademarks or companies It is the sole responsibility of the user to determine the suitability of this product for his or her use and the user shall assume all legal personal injury risk and liability and all other as well as all other obligations duties and risks associated therewith CUSTOMER SUPPORT For any installation or service questions please contact our BAKER technical department toll free 1 877 640 2004 PAGE 12 DISCLAIMER v 11 041015 9804 E SAGINAW HASLETT MI 48840 TOLL FREE 1 877 640 2004 PAGE 13 NOTES
5. ccording to the Factory Service Manual you want to place the shifter pawl on the top cover mounting surface with the gasket acting as a pad while pulling the gearset 5 Now you can unbolt the trap door from the case Lightly tap on the end of the mainshaft on the primary side with a rubber mallet to loosen the entire gearset and trap door from the case and the 6th main needle bearings Set the gearset aside on the workbench as you do not need any parts from it for this installation Use the main drive gear and bearing service tool of your choice and while following the Factory Service Manual remove the 6th main Drive gear seal snap ring and bearing Now is a good time to clean out the case the main drive gear bearing bore the top cover and bearing door gasket surfaces of any debris to prevent leaks in the future 6 Remove the stock shifter pawl assembly PAGE 7 ASSEMBLY v 11 041015 BAKER DD7 BUILDERS KIT INSTALLATION GEARSET INSTALLATION 1 Install the provided BAKER Shifter Pawl using the supplied seal washer and snap ring 2 Still following the Factory Service Manual press the provided Main Drive Gear Roller Bearing pn 8967 into the case Install the provided Beveled Snap Ring pn 1302 334PP at this time with the beveled edge of the snap ring facing you NEVER INSTALL THE BEARING INTO THE CASE BY APPLYING PRESSURE TO THE al INNER RACE OF THE BEARING YOU WILL DESTROY THE BEARING AND IT MAY FAIL IN THE FUTURE 3
6. decreased friction while increasing smoothness when coupled with the all new shift drum design We have tightened up the dog teeth on the gears to prevent the loud clacking noise that accompanies every shift on the factory 6 speed Through the use of a billet bearing door 28 wider bearings in the door steel bearing retainer plates and full width gears the durability and strength of our unit is a drastic improvement By utilizing fully diamond ground helical gears in 1st amp 4th 7th we are able to deliver a much quieter riding experience While 2nd and 3rd gears are diamond ground spur gears to handle the peak torque that is reached in that range Stock Ratios DD7 Ratios 1st 3 34 1st 3 76 2nd 2 30 2nd 2 75 3rd 1 71 3rd 2 06 Ath 1 41 Ath 1 55 5th 1 18 5th 1 27 6th 1 00 6th 1 10 7th 1 00 FITMENT 2006 Later Dyna 2007 Later Touring 2007 Later Softail Fitment Note The 6th gear indicator light will come on when the DD7 is shifted into 7th on all models and all ECM s Aftermarket tuners such as Daytona Twin Tec and TTS Mastertune will allow cruise to function in all gears like stock on Throttle By Wire bikes when coupled with the DD7 gearset Any questions on this please give our tech line a call PAGE 2 OVERVIEW v 11 041015 BAKER 007 INSTALLATION INSTRUCTIONS TABLE OF CONTENTS 2 3 4 5 6 7 Disassembly Stock Gearset Removal Case Prep 8 9 DD7 Gearset Installation 10 Final Assembly 11 Ter
7. e Standard BAKER FF Hydraulic Side Cover P N DD7 106B KIT Hog Black Standard Dakota Digital Programmable Gear Indicator Chrome Finish Flush Mount For Fairings P N P6R 1000 F Handlebar Mount Version 7 8 1 1 2 Bars P N P6R 1 PAGE 4 SKILLS TOOLS amp KNOWLEDGE v 11 041015 BAKER DD7Z BUILDERS KIT INCLUDED PARTS DETAIL DD7 Gearset Cassette Main Drive Gear Bearing pn 8967 Main Drive Gear Seal pn 12074 Main Drive Gear Snap Ring pn 1302 334PP Bearing Door Bolts 18 8 Stainless Steel Socket Bearing Door Gasket pn 35654 06 Head Bolts 8 pcs pn 73497 Top Cover Gasket 3491 7 06 Washers 8 pcs pn 6100 Side Cover Gasket pn 36805 06 Speed Sensor Gasket pn 133 56R GAS BAKER Shifter Pawl pn 555 07 A Bearing Inner Primary Race pn 34091 06 Snap Ring pn 68010 Side Cover Emblem pn DD7 108 Seal pn 37101 84B Washer pn 6497HW H D PAGE 5 INCLUDED PARTS DETAILS v 11 041015 DD7 GEARSET LAYOUT Mainshaft amp 1st Gear pn DD7B MS O Ring Main Drive Gear pn ORS68133 Fork Rod M S pn 35222 06 Main Drive Gear 7th pn DD7 7M th 7th Gear Dog Clutch pn DD6 4C5 th Gear pn DD7A 6M 51h Gear pn DD7A 5M Ath 5th Gear Dog Clutch pn DD A DC45 Ath Gear pn DD7A 4M 2nd Gear pn DD7 2M 3rd Gear Dog Clutch pn DD7A DC3 3rd Gear pn DD7A 3M Mainshaft amp 1st Gear pn DD7B MS th 7th Gear Shift Fork pn DD7D 104 Ath 5th Gear Shift Fo
8. et in IF YOU FEEL THAT THE TRANSMISSION IS NOT SLIDING IN JOSTLE THE MAIN DRIVE GEAR TO HELP THE COUNTERSHAFT MESH WITH IT AND CHECK TO MAKE SURE THE FORK RODS ARE IN PLACE ON THE BACK SIDE OF THE BEARING DOOR AS THOSE COULD BE THE CULPRITS 5 Find the 8 provided 18 8 Stainless Steel Socket Head Bearing Door Bolts pn 73497 in the Builders Kit box using Blue Thread Lock place them in the bearing door and torque to 220 in Ibs while following the torque sequence See Figure 4 Make sure to put in place any exhaust brackets before tightening down the bolts GEARSET INSTALLATION CONTINUED ON NEXT PAGE PAGE 8 ASSEMBLY v 11 041015 BAKER DD7 BUILDERS KIT INSTALLATION FIGURE 4 GEARSET INSTALLATION CONTINUED 6 Re install your Factory top cover using the supplied gasket and following your Factory torque sequence and procedure 7 While following the Factory Service Manual slide the pulley into place on the new 7th Main Drive Gear and torque to spec while making sure to install the nut lock plate and retaining bolts 8 In accordance with the Factory Service Manual install the Neutral Sensor Dipstick to keep debris out of transmission and the Transmission Side Cover 9 After properly bolting down the side cover clean the side cover thoroughly of dirt oil and emblem residue and apply the included 7 Speed Side Cover Emblem pn DD7 108 Firmly push the emblem onto your side cover Some cable style side cove
9. ms Overview Table Of Contents Skills Tools amp Knowledge Included Parts Breakdown Gearset Layout uuu NA 12 Disclaimer 13 Notes PAGE 3 TABLE OF CONTENTS v 11 041015 SKILLS TOOLS amp KNOWLEDGE REQUIRED READING Regardless of the skill level or experience of the installer of the DD7 Builder s Kit it is highly recom mended that a genuine H D Motor Company parts catalog and Factory Service Manual be available for reference for your type of bike TOOLS Common Hand Tools Allen Wrenches Sockets Snap Ring Pliers Etc e Torque Wrench 3 8 amp 72 Drive 1 3 16 6 Pt Socket Clutch Nut Inner Primary Race Service Tool BAKER pn TOOLB 56 HD Equivalent pn 34902B Main Drive Gear amp Bearing Service Tool BAKER pn ToolA 07 HD Equivalent pn 35316C Pulley Locking Tool BAKER pn TOOLC 56 HD Equivalent pn 46282 Pulley Nut Socket BAKER pn TOOLD 07 HD Equivalent pn 47910 Primary Fluid 45 oz Needed BAKER Recommends Spectro Heavy Duty Primary Chain Case Oil pn R GAPCL Transmission Fluid 32 oz Needed BAKER Recommends Spectro Heavy Duty Platinum 6 Speed Transmission Oil pn BD 75140 32 elt is recommended that the Countershaft Bearing is replaced at the time of installation using an approved tool and procedure such as the Jims Countershaft Cup Bearing Tool JIMS USA PNZ739 P 805 482 6913 OPTIONAL PARTS BAKER FF Hydraulic Side Cover P N DD7 106C KIT Chrom
10. rk pn DD7C 103 Shift Drum Assembly pn DD7A 100 A Countershaft amp 7th Gear pn DD7 CS th Gear pn DD7A 6C 51h Gear pn DD7 5C Fork Rod C S 4h Gear mmm d d rim TS Eh HU Adi reat REI 7 pif ae Pe 4 421 0 10mm Hollow Dowels 16583 00 Side Cover Dowels Bearing Door pn 26735 DD D 107 C 3rd Gear Shift Fork pn DD7B 102 1st 2nd Gear Shift Fork pn DD7B 101 v 11 041015 BAKER DD7 BUILDERS KIT INSTALLATION CASE PREPARATION GEARSET REMOVAL 1 Whereas it may seem as we are skimming over many of the steps your Factory Service Manual will lay out in detail the proper methods for removal and reassembly of the components listed out in the steps within these instructions Softails Dyna s and Touring Models are all different configurations and require a different order and method to accomplish the various steps py SIMILAR TO ANY OTHER DRIVETRAIN RELATED PROJECT THE FIRST STEPS THAT YOU WANT TAKE ARE TO REMOVE THE SEAT AND DISCONNECT THE BATTERY FOR YOUR OWN SAFETY NOW IS A GOOD TIME TO GET OUT A COUPLE OF DRAIN PANS AND DRAIN THE PRIMARY FLUID AS WELL AS THE TRANSMISSION FLUID FOR LOCATION OF THE APPLICABLE DRAIN PLUGS CHECK YOUR SERVICE MANUAL 2 Next remove the saddlebags if applicable then the floorboards pegs and the pipes
11. rs already have a 6 speed emblem on them with some heat from a heat gun and a thin putty knife this will easily pull off 10 Before reassembling the motorcycle install the Vehicle Speed Sensor Gasket pn 133 56R GAS under the factory VSS Vehicle Speed Sensor It is located under the starter on the backside of the transmission case Refer to factory service manual for exact location Installation of this gasket will make the speedometer easier to re calibrate by bringing the air gap from the VSS to the 6th main gear under it up to factory specifications PAGE 9 ASSEMBLY v 11 041015 BAKER DD7 BUILDERS KIT INSTALLATION MOTORCYCLE REASSEMBLY 1 With the transmission installed you are ready to start reassembly of your motorcycle While referencing the Factory Service Manual install the Starter Inner Primary Race Inner Primary Chain Tensioner Mechanism Clutch Motor Sprocket Primary Chain Assembly Outer Primary Exhaust Saddlebags if applicable Seat Foot Controls and Connect the Battery Fill the Primary and Transmission with Fluids According to the Factory Sevice Manual Transmission 32 Fluid OZ Primary 45 Fluid Oz 2 Adjust the clutch per the Factory Service Manual FINISH LINE When you have successfully reassembled your motorcycle take the time to double check that you have replaced all of the parts and that none are left on the lift garage floor work bench etc Double check to make sure that you pu
12. t Primary and Transmission Fluid in the bike Take the time to double check the drain plugs are tight and to wipe down the bearing door side cover and primary to make sure there are no leaks after the maiden voyage When you take off for your test ride ease into it and slowly accelerate through the gears to ensure that you reassembled the motorcycle in a functional and safe manner You have now successfully completed the installation of the BAKER DD7 Enjoy PAGE 10 ASSEMBLY v 11 041015 SPECIAL ORDERS A minimum 500 deposit is required with all special orders Special orders include unique case finishes unique side door requests i e wrinkle black door or no logo ALL OTHER ORDERS Orders can be pre paid using VISA Mastercard or American Express Prices shown are F O B Haslett BAKER provides free UPS ground shipping on all retail orders for complete transmissions or transmission kit UPS air shipment is available upon request Customer is responsible for air shipment premiums LIMITED WARRANTY BAKER Inc transmission assemblies transmission kits and wide tire kits are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of 5 years from the date of purchase or up to 50 000 miles whichever is sooner If the product is found by BAKER to be defective such products will at the option of BAKER be replaced or repaired at cost to BAKER
13. v 11 041015 BAKER DD7 INSTALLATION INSTRUCTIONS ETRA FOR AMERICAN MOTORCYCLES PAGE 1 OVERVIEW v 11 041015 FEATURES The all new BAKER DD7 is more than just another gear added to the mix for the sake of one upmanship That 7th gear enables the motorcycle to now make full use by way of gear ratio management of the torque and power put out by the new 96 ci and 110 ci motors rolling off the assembly line in Milwaukee We did not make this Transmission a deep overdrive rather we shortened 1st gear and tightened up the gears to deliver the riding experience that you were after when you bought your bike The gear ratios as listed out below leave you the rider with the experience of smooth crisp continuously pulling acceleration from 1st all the way through 4th gear Then you are able to start getting into the cruising portion of the program in gears 5th 7th No big drops in RPM from one gear to the next or lugging the motorcycle off of a stop light just smooth uninhibited acceleration We did not stop at just fixing the gear ratios We improved the smoothness and crispness of the shifting by reducing the mainshaft mass by only having 1st gear be a part of the shaft rather than 1st 4th gears like on the stock unit Reduction in rotating mass for shift quality is a fact that has been utilized in the automotive world for years We ditched the stock detent arm and spring assembly from the door in favor of a Linear Detent that
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