king kong clutch installation instructions
Contents
1. Om He OO CUSTOMERS PREFERENCE R Description 1 4 20 X 13 4 SHCS INNER HUB FLANGE BACKING PLATE 1 4 20 X 5 8 SHCS 1 7 16 INTERNAL SNAP RING 1 1 2 LEFT HAND THREADED RETAINER FLANGED HUB BASKET CLUTCH CARRIER CLUTCH 10 32 X 1 2 FSHCS BEARING INA DOUBLE ROW CARRIER SNAP RING EXTERNAL FLANGED HUB SNAP RING INTERNAL 72MM CARRIER SPROCKET 35 TOOTH SPROCKET 36 TOOTH SPROCKET 37 TOOTH SPROCKET 38 TOOTH 5 16 18 X 3 4 SHCS SPROCKET PAGE 4 PARTS xa xa BAKER KING KONG CLUTCH INSTALLATION PREPARATION DISSASSEMBLY 1 FOR YOUR SAFETY DISCONNECT BOTH BATTERY POSTS FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY 2 Remove primary drain plug located at the bottom of your primary drain fluid and dispose of at your local recycler 3 On some models it is necessary to remove foot pegs floor boards in order to remove the outer primary 4 Remove the outer primary cover 5 Refer to your Factory Service Manual to remove your stock clutch assembly and related primary components using the proper safety precautions and tools 1994 2006 EXCEPT 2006 DYNA MOTORCYLCES REQUIRES THE USE OF THE BAKER 9 TOOTH STARTER PINION P N SP1000 WHICH CONVERTS YOUR 102 TOOTH CLUTCH CONFIGURATION INTO A 66 TOOTH CONFIGURATION TO WORK WITH OUR CLUTCH BASKET PINION REPLACMENT 1 With Clutch assembly primary components out of the way remove t2. V 5 TABLE OF CONTENTS 1 Overview 2 Table of Contents 3 4 Included Parts Detail 5 Stock Bike Disassembly 6 9 Step by step installation 10 Terms 11 Disclaimer PAGE 2 TABLE OF CONTENTS INCLUDED PARTS PARTS PROVIDED WITH THE BAKER KING KONG CLUTCH ON 8 Nu aX 7 i Se 4 X N N X Q SOD A AN vA x N Figure 1 ed e amp THE FOLLOWING PARTS INCLUDED AS SHOWN IN FIGURE 1 FIGURE 1 P N Description 1 23202 3 1 4 20 X 5 8 SHCS 2 36258 1 7 16 20 JAM NUT GRADE 8 3 9P235 56 1 ADJUSTER SCREW 4 20P107 KK 1 KEY HOLE FITTING 5 004 242 6 1 4 28 X 5 8 SHCS 6 20P111 KK 6 SPRING CUP POLISHED 7 LC 095J O5M 6 SPRING YELLOW 240 lbs 7 LC 105J O5M 6 SPRING RED 360 Ibs 7 LC 112J O5M 6 SPRING BLUE 480 Ibs 8 PAPZ1004P10 6 PERMA GLIDE BUSHING 9 20P105 KK 1 PRESSURE PLATE 10 156702 160 10 INTERNAL SPLINED FRICTION PLATE 10 156703 160 10 EXTERNAL SPLINED FRICTION PLATE PAGE 3 PARTS INCLUDED PARTS PARTS PROVIDED WITH THE BAKER KING KONG CLUTCH CONTINUED Figure 2 THE FOLLOWING PARTS ARE INCLUDED AS SHOWN IN FIGURE 2 FIGURE 2 P N 11 002 359 12 20P101 KK 13 20P104 KK 14 23202 15 143RRRI 16 732121 17 20P103 KK 18 20P100 KK 19 20P102 KK 20 10FSOKFC 21 3207 22 1460 137PP 23 35258 24 4 35 24 4 36 24 4 37 24 4 38 25 23253
3. NESSESSARY FOR PROPER FITMENT 7a Using a die grinder or cut off wheel remove the cast webbing from the inside of the inner primary Remove webs entirely until smooth with the inside face Figures 4 and 5 A total of 8 ribs will be cut 7B CHECK YOUR OUTER PRIMARY FITMENT TO MAKE SURE YOU HAVE PROPER CLEARANCE WITHOUT GASKET INSTALLED EXTRA GRINDING MIGHT BE REQUIRED CLUTCH SHOULD SPIN FREELY WITH FULL CLUTCH ACTUATION FAILURE TO CHECK MIGHT RESULT IN DAMAGE TO THE CLUTCH INNER AND OUTER PRIMARY RING GEAR AND OR PERSONAL INJURY 8 Install outer primary with new gasket following the Factory Service Manual FLH models require James Gasket P N 34901 94 Softail Dyna models 94 06 except 06 Dyna require James Gasket P N 60539 94 9 Add ATF Automatic Transmission Fluid Dexron Mercon available at your local auto parts store referring to your Factory Service Manual for proper fluid level specifications DUE THE KING KONG CLUTCH HIGH PERFORMANCE CLUTCH ASSEMBLY WE RECOMMEND ONLY THE USE OF ATF AUTOMATIC TRANSMISSION FLUID ATF HAS FRICTION MODIFIERS AND BETTER LUBRICATION CHARACTERISTICS THAN FOUND IN ORDINARY PRIMARY FLUID THE USE OF ORDINARY PRIMARY FLUID COULD CAUSE THE CLUTCH TO SLIP AND DRAG RESULTING IN CLUTCH FAILURE AND VOIDING YOUR WARRANTY 10 Install derby cover clutch inspection cover with new gasket Following your Factory Service Manual specifications 11 If floor boards or pegs were rem
4. KING KONG CLUTCH INSTALLATION INSTRUCTIONS PREMIUM DRIVETRAIN INNOVATIONS FOR AMERICAN MOTORCYCLES BAKER KING KONG CLUTCH V 05 091008 FEATURES 1 Piece steel clutch basket design 66 tooth ring gear configuration 23 thicker than stock 20 massive 7 diameter single sided friction plates Red hard anodized carrier and pressure plate Hard anodized inner hub for wear resistance e Positive pressure plate alignment accomplished with teflon coated perma glide bushings Coil spring design with 3 different springs included APPLICATION AND REQUIRED HARDWARE 1990 2006 Softail Dyna Applications Except 2006 Dyna Motorycles 94 06 Softails require James Gasket P N 60539 94 thicker than stock 1994 2006 FLH Models James Gasket P N 34901 94 is required thicker than stock SKILL LEVEL As with most things in life there is no substitute for skill and experience It is highly recommended by BAKER Drivetrain that when performing this task or any task related to the Drivetrain components on your motorcycle that you refer to your Factory Service Manual for your specific model of bike SPECIAL TOOLS e 1 3 16 Socket clutch nut removal 1 Socket compensating sprocket nut Torque wrench 3 16 T Handle allen Die grinder or cut off wheel for 94 06 Big Twin Except 06 Dyna Motorcycles e ATF Dexron Mercon fluid PAGE 1 OVERVIEW BAKER KING KONG CLUTCH INSTALLATION
5. he factory 10 tooth starter pinion H D P N 31342 94 STOCK po Replace the factory pinion with BAKER S 9 Tooth Starter Pinion P N SP1000 refer to the Factory Service Manual for proper torgue specifications while reusing the Factory Hardware Fig 3 BAKER DRIVETRAIN CLUTCH ASSEMBLIES ALL COME PREASSEMBLED AND READY FOR INSTALLATION FRICTION PLATES ARE PRESOAKED AT OUR FACILITY AND READY TO RUN Figure 3 PAGE 5 ASSEMBLY BAKER KING KONG CLUTCH INSTALLATION INSTALLATION OF YOUR BAKER KING KONG CLUTCH 1 Install your new clutch assembly primary chain and motor sprocket components following the Factory Service Manual figure 1 2 Install the factory clutch nut H D P N 37496 90 with the machined relief facing toward the clutch using Red thread lock 3 Install compensating sprocket nut using Red Thread Lock Figure 1 4 Torque clutch and compensating nut to Factory specifications found in your Factory Service Manual 5 Adjust primary chain following steps listed in your Factory Service Manual 6 Install clutch adjuster Key Hole Fitting with bolts provided in kit using blue thread lock Torque bolts to 110 in Ibs figure 3 PAGE 6 ASSEMBLY xa xa BAKER KING KONG CLUTCH INSTALLATION 7 Adjust the clutch following steps listed in your Factory Service Manual FOR 1994 2006 SOFTAIL DYNA EXCEPT 2006 DYNA MOTORCYCLES MODIFICATION TO THE INNER PRIMARY IS
6. 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 10 TERMS 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 11 DISCLAIMER
7. installing the retaining bolts using blue thread lock Torque to 110 in lbs a star shaped pattern 7 Remove the 2 springs that you left in Step 5 Replace them with the remainder of the desired springs using blue thread lock torque to 110 in Ibs 8 Readjust the clutch following your Factory Service Manual 9 Install derby cover clutch inspection cover per Factory Service Manual PAGE 8 ASSEMBLY BAKER KING KONG CLUTCH INSTALLATION KING KONG CLUTCH SPRING CHART There are 3 different springs available for your clutch We recommend the following Yellow P N LC 095J 05M for stock applications Red P N LC 105J 05M for modified motors up to 150 h p Blue LC 112J 05M recommended for race applications only Motors over 150 h p NOTE A motorcycle being shifted with the throttle wide open will require more spring pressure than shifting with the throttle rolled closed Of Yellow Yellow Red Red Blue Springs Spring Red Spring Blue Spring Lo 240 Ibs 360 480 Ibs Ibs ET PS T S 3 of 300 420 me te BAKER Drivetrain does not recommend altering the spring pressures other than specified above Doing so could result in clutch damage failure void of warranty loss of control and or personal injury PAGE 9 ASSEMBLY SPECIAL ORDERS A minimum 500 deposit is reguired with all special orders Special orders include unigue case finishes unigue
8. 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 damages 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 clutches primaries belt drives 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
9. oved to install your clutch reinstall them as per Factory Service Manual BEING A Figure 4 Before removal of casting webs After removal of 8 casting webs Figure 5 ENSURE A LONG SERVICE LIFE FOR YOUR NEW BAKER KING KONG CLUTCH RE ADJUST THE CLUTCH PER MANUAL AFTER THE INITIAL BREAK IN PERIOD THIS CAN VERY DEPENDING ON YOUR RIDING STYLE BETWEEN 500 3000 MILES PAGE 7 ASSEMBLY BAKER KING KONG CLUTCH INSTALLATION Your BAKER KING KONG CLUTCH is shipped with our red medium springs installed rated at 60 Ibs each Depending on your riding style you can alter or tailor your spring load following the steps listed here NOTE WHEN YOU CHANGE SPRING PRESSURE YOUR LEVER EFFORT WILL ALSO CHANGE INSTALLATION OF COIL SPRINGS Refer to the exploded view 1 and Figure 6 as a guide 1 Make sure the motorcycle is supported correctly on a lift or kickstand 2 Put the motorcycle in 1st gear this will help when removing the coil springs 3 Remove the derby cover clutch inspection cover Figure 6 4 Loosen the clutch adjustment 5 Using a 3 16 T handle allen remove 4 of the 6 springs leaving 2 springs 180 degrees apart This is to hold the clutch pressure plate and clutch pack together 6 Reference the spring chart on page 9 if mixing the springs mix equally every other one install 4 of the desired springs some pressure is required on the T handle when
10. side door reguests 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 primaries belt drives 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 BAKER clutches are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of 2 years from the date of purchase or up to 24 000 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 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
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