overview - Baker Drivetrain
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1. PAGE 2 TABLE OF CONTENTS INCLUDED PARTS PARTS PROVIDED WITH THE BAKER DD6 BUILDERS KIT THE FOLLOWING PARTS ARE INCLUDED AS SHOWN IN FIGURE 1 1 Assembled DD6 gear set on BAKER bearing door 2 Shift drum with redundant neutral pillow blocks 3 Shifter pawl model specific 4 New P N 6209 main bearing and beveled snap ring o Three shift forks labeled 2 3 and 4 6 Bearing grade fork rod 7 28t Compensating sprocket and chain model specific 8 Primary Shaft Race OTHER PARTS INCLUDED NOT SHOWN IN FIGURE 1 9 Neutral switch some models 10 Replacement chain tensioner pad and hardware some models 11 Eccentric adjuster screw 12 Seal 12067B PAGE 3 PARTS BAKER DD6 BUILDERS KIT INCLUDED PARTS DETAIL DD6 SHIFT DRUM GEARSET ge PAN PW 124D DD6 401 2 94 15 OR 411 3 24 1ST FORK ROD GASKET SET PIN PNS 122 6 36801 87B SIDE COVER 35652 79B TRAP DOOR 34904 86 PRIMARY RACE PAN 34091 85X SHIFT FORKS PNS 172 DD6 173 DD6 MAIN BEARING PAN 174 DD6 6209 SPROCKET PAN SHIFTER PAWL 158 56 PAN 555 56A OR 555 56L PAGE 4 PARTS INCLUDED DETAILS EXPLODED VIEW DIAGRAMS SHIFT SYSTEM VIEW 1 gt K NUMBER PART NUMBER DESCRIPTION OTY 1 23207 1 4 20 x 1 1 4 SHCS Plain 4 2 33001 3 16 washer plain 4 3 124E DD6 A Shift System DD6 1 4 609B Alignment pin 5 16x3 8 4 5 122 6 Fork Rod 62. DIRECT DRIVE G SPEED FEATURES DD6 TRANSMISSION BUILDERS KIT The BAKER DD6 transmission Builders Kit comes with the necessary components to change your stock 5 Speed into a 6 Speed providing smoother shifting positive neutral finding and reduced cruising RPM on the highway as compared to the stock 5 speed With proven technology and helical 4th 5th and 6th gears your highway cruising is noise free APPLICATION AND REQUIRED HARDWARE A Builder s Kit is as the name implies for building a BAKER DD6 transmission using an existing case housing and its peripheral hardware The following 5 speed components are required to complete this installation Transmission case o Pawl and sprocket spacer seals Top cover and fasteners o Clutch release cover amp fasteners Clutch release mechanism and push rod hardware PAGE 1 OVERVIEW BAKER DD6 INSTALLATION INSTRUCTIONS TABLE OF CONTENTS 3 DD6 Builders Kit Included Parts 4 DD6 Builders Kit Included Parts Detail o DD6 Exploded View Diagrams 9 Skills Tools and Knowledge 10 DD6 Builders Kit Assembly Prep Checks Gear installation 11 DD6 Builders Kit Assembly Gear installation continued 12 DD6 Builders Kit Assembly Forks Checks Drum 13 006 Builders Kit Assembly Shifter pawl neutral switch installation 14 006 Builders Kit Assembly Primary chain and sprocket 15 DD6 Builders Kit Assembly speedo sensor and fluids 16 Terms 17 Disclaimer
3. 2 25 125 55 1 4 20 x 1 1 4 SHCS polished SS 6 3 6099SS Washer Stainless Steel 13 4 33902 98 Switch Neutral Indicator 1 5 34468 56A Top Cover LSD 91 98 ST 1 6 34904 86E Gasket Top Cover forged 1 7 609B alignment dowel 4 8 214C 56CB BAKER trans housing 1 9 26770 dowel starter 1 10 37089 84 Cltuch Rod 5spd 1 11 TWCA11 thrust washer throw out 2 12 TC411 Bearing clutch rod roller 1 13 37088 90 Clutch Rod 1 14 10705 01149 C Clip 1 15 66853 o ring 216 2 16 124 5L38 piston 1 375 bore 1 T 459 6 Chrome Hydr Clutch Cover Indian 1 18 45 9404 bleeder valve 1 19 25C225KCSS P 1 4 20 x 2 1 4 SHCS polished SS 2 20 25C125KCSS P 1 4 20 x 1 1 4 SHCS polished SS 4 21 130 56BSP Dipstick 1 22 66825 o ring dip stick 1 23 1302 334PP 3 11 32 internal snap ring beveled 1 24 36801 87B Gasket Right Side Cover 1 25 24050 1 4 20x5 8 BHCS bearing retainer plate 1 26 37141 3 4 16 Jamnut 2 27 6304 Bearing trap door 2 28 6100 5 16 washer 4 29 31C125KCSS P 5 16 18 1 1 4 polished SS SHCS 4 30 133 DD6 bearing retaining plate 1 31 23202 1 4 20 5 8 SHCS bearing retainer plate 5 92 51740 001 3 8 24 drain plug 1 33 132A DD6 E Bearing Door w ear indian logo 1 34 35652 79B Gasket Bearing Retainer 1 35 F1409 Door Magnet 1 36 29205 1 4 20 x 1 SHCS 1 37 11733A Stud Rigid transmission 5 38 2526 Bearing C S Case 1 39 12067B Main Seal 1 40 33344 945 Pulley Spacer 1 41 11165A quad seal 1 42 6209 Bearing main drive gear 1 PAGE 8 EXPLO
4. speed BAKER 1 6 172 DD6 Fork 2nd MS 1 7 173B DD6 Fork 3rd C S 1 8 174 DD6 Fork 4 5 MS 1 9 555 56A Ratchet Pawl anti overshift Rev A 1 10 337 15 855 Shift Lever stainless steel 1 11 31F100KCSS P 5 16 24 x 1 SHCS Polished 1 12 70813 7 16 14 Jamnut stainless steel 1 13 152 56A Eccentric Adjuster 1 14 25702 1 2 20x1 2 SET SCREW 1 15 68010 7 1 6 ext snap ring 1 16 6497HW washer shift shaft 1 17 12045 Seal Shift Lever 1 18 33114 79A Bushing Shifter Pawl 1 PAGE 5 EXPLODED VIEW DIAGRAMS EXPLODED VIEW DIAGRAMS GEARSET PN DESCRIPTION OTY 1 12035B Oil Seal Maindrive 1 2 HK2520 Bearing 6th maindrive assembly 2 3 DD6 6M 1 BAKER DD6 6th MN 1 4 DD6 2M 1 BAKER DD6 2nd MN 1 5 11067 Retaining Ring 5 6 6003B Thrust Washer 5 7 DD6 3M 1 BAKER DD6 3rd MN 1 8 8876A Cage Bearing 5 9 DD6 4M 1 BAKER DD6 4th MN 1 10 DD6 4C5 1 BAKER DD6 4 5 clutch gear 1 11 DD6 5M 1 BAKER DD6 5th MN 1 12 TWD1423 Thrust Washer 2 13 DD6 MS 2 94 BAKER DD6 mainshaft 2 94 1st stock 1 13A DD6 MS BAKER DD6 mainshaft 3 24 1st optional 1 14 DD6 CS BAKER DD6 CS CLUSTER 2 94 1st stock 1 14A DD6 CS BAKER 006 CS CLUSTER 3 24 1st optional 1 PAGE 6 EXPLODED VIEW DIAGRAMS EXPLODED VIEW DIAGRAMS TRANSMISSION HOUSING VIEW 3 01 PAGE 7 EXPLODED VIEW DIAGRAMS EXPLODED VIEW DIAGRAMS THE FOLLOWING PARTS ARE INCLUDING AS SHOWN IN TRANSMISSION HOUSING VIEW 3 NUMBER PN DESCRIPTION OTY 1 25C225KCSS P 1 4 20 x 2 1 4 SHCS polished SS 1
5. AR LUBE INCLUDED IN YOUR KIT IS APREMEASURED BOTTLE FOR YOUR CONVENIENCE PAGE 15 ASSEMBLY SPECIAL ORDERS A minimum 500 deposit is reguired with all special orders Special orders include unigue case finishes unigue side door reguests 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 MI BAKER provides free UPS ground shipping on all retail orders for complete transmissions or transmission kit UPS air shipment is available upon reguest 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 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 BA
6. DED VIEW DIAGRAMS SKILLS KNOWLEDGE 8 TOOLS REOUIRED READING Regardless of the skill level or experience of the installer of the Builder s Kit it is highly recommended that a genuine H D Motor Company parts catalog and Factory Service Manual be available for reference on the installation The installation instructions for the BAKER DD6 will make reference to the Factory Service Manual Any Factory manual from 1990 to present will be sufficient SPECIAL TOOLS The only special tools required are the same tools that would be required for any 5 speed installation For a list of other required tools please consult your Factory Service Manual For removing and installing of the main drive gear and main drive bearing BAKER DRIVETRAIN part number TOOLA 56 is required an equivalent tool is also available from your local Harley dealer part number 35316A TOOL A 56 p M For removing and installing the bearing inner race on the transmission mainshaft BAKER DRIVETRAIN part num ber TOOLB 56 is necessary Harley also offers an eguiv TOOL B 56 alent tool 34902A For removing and installing the 1 7 8 transmission pulley nut BAKER DRIVETRAIN part number TOOLD 56 will be TOOLC 6 needed The Harley part number is 94660 37A J TOOL D 56 PAGE 9 SKILLS KNOWLEDGE AND TOOLS BAKER DD6 BUILDERS KIT ASSEMBLY CASE PREPARATION GEARSET REMOVAL If the Builder s Kit is replacing an existing 5 speed refer to yo
7. KER 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 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 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 appli
8. P 4 ys lt E HANGING THE DOOR GASKET 4 Hang the door gasket provided onto the case dowel pins and carefully push it down to seat it against the gasket surface 5 Apply some WD 40 or equivalent lubricant to the main drive gear seal and to the mainshaft on the portion adjacent to the splines Install the gearset by sliding the mainshaft through the main drive gear and slowly pushing the gearset assembly until the case dowel pins contact the dowel holes in the side door Be sure that the threads in the end of the mainshaft do not contact the seal in the main drive gear If the shaft tears the seal leakage will occur A rubber hammer is helpful to tap the bearing door gently WARNING IMPACTING THE ENDS OF THE TRANSMISSION SHAFTS WILL CAUSE THE DOOR BEARINGS TO FAIL FIGURE 5 6 Install the four 5 16 18 x 1 1 4 SHCS socket head cap screws along with the washers in the lower MU four holes in the bearing door Use a small amount of Blue thread locker on the end of the threads and Ju STEP 6 torque the bolts to 13 16 ft Ibs 156 192 in Ibs UR Install the two 1 4 20 x 1 1 14 with washers in the SHCS same manner above the dowel pin holes and torque them to 7 9 ft Ibs 84 108 in Ibs FIGURE 7 PAGE 11 ASSEMBLY BAKER DD6 BUILDERS KIT ASSEMBLY SHIFT FORK INSTALLATION PROPER SHIFT FORK ALIGNMENT Figure 8 shows the proper placement of the shift forks Fork number 4 is placed on the sh
9. cation 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 16 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 17 DISCLAIMER As R VETRANIE RIVETRAIN INNOVATIONS FOR AMERICAN MOTORCYCLES 9804 E SAGINAW HASLETT MI 48840 TOLL FREE 1 877 640 2004
10. ift clutch between the 4th and 5th gears on the mainshaft It will be necessary to engage the 4th gear on the mainshaft with the shift clutch This will make installing the number 4 fork easier Fork number 3 is placed on the 3rd countershaft gear Fork number 2 is placed on the 2nd mainshaft gear To simplify installation slide the 2nd mainshaft gear into the 3rd gear on the mainshaft This provides adequate room to slide the fork into the fork groove Install the primary fork rod as you would in a stock 5 speed transmission through the holes in the forks Once assembled the shift system should appear as shown in Figure 8 FIGURE 8 FUNCTION CHECK The three forks should operate smoothly along the bearing grade fork rod once installed If binding occurs check for proper placement and or obstructions inhibiting the ease of fork movement At this time apply a generous amount of WD 40 or transmission oil to the forks and fork rod SHIET DRUM SHIFT DRUM DETENT SYSTEM The shift drum and pillow block system of the BAKER DD6 transmission was designed with low friction and ease of operation in mind Inside the shift drum is a ball bearing that reduces friction No shimming or setup is required with the shift drum and pillow block system The right side pillow block has another provision known as redundant neutral detent The redundant neutral feature of the drum aids in finding neutral with less effort FIGURE 9 Install
11. pplication situations you will have to heli coil the outer primary cover for the two bolts that you clearanced FIGURE 14 For most older applications you will be able to flip the entire tensioner Figure 16 upside down Figure 2 and that will accomplish the difference required We do not recommend using auto tensioners from any manufacturer with our DD6 Builders Kit FIGURE 16 FIGURE 17 PAGE 14 ASSEMBLY BAKER DD6 BUILDERS KIT ASSEMBLY SPEED SENSOR INSTALLATION Provided in the kit is a speed sensor spacer Remove the speedometer sensor from the transmission case and place the spacer plate paper gasket under the stock sensor This is important to maintain proper spacing to the 5th gear on the mainshaft The gasket is only 060 thick so be careful not to over torque it You may require a speed sensor signal conversion box to correctly re calibrate the speedo head This unit and is available from BAKER DRIVETRAIN part number 95E 56 FLUID FILL Fluid capacity is 20 24 fluid oz of one of the following recommended oils BAKER recommends using Spectro Heavy Duty 6 Speed Gear Lube which we have included in your DD6 kit in a premeasured bottle One of the following oils can be used Spectro 75W 140SPL Bel Ray 80W 90 Torco 85W 140 AMSOIL 75W 90 BAKER SPEED SENSOR SIGNAL CONVERSION BOX PART NUMBER 95E 56 BAKER DRIVETRAIN RECOMMENDS USING SPECTRO HEAVY DUTY 6 SPEED GE
12. the new main drive gear bearing provided O E P N 6209 NEVER install the bearing into the case by applying pressure to the inner race of the bearing you will destroy the bearing and it may fail Install the new retaining ring with the bevel facing Out FIGURE 2 2 Remove the main drive gear from the BAKER DD6 gearset trap door assembly by simply sliding it off the mainshaft To install the main drive gear into the transmission case use BAKER DRIVETRAIN part number TOOLA 56 and follow the directions as described in the Factory Service Manual STEP 2 REMOVING THE MAIN DRIVE GEAR FIGURE 3 PAGE 10 ASSEMBLY BAKER DD6 BUILDERS KIT ASSEMBLY aa STEP 3 INSTALLING THE SHIFTER PAWL AND SNAP RING All models require the changing of the eccentric adjustment screw for proper shift pawl adjustment 2000 06 Softails and all 01 06 FLT and 05 Dyna models will require this change The adjustment screw and locking nut are provided in the Builder s Kit 3 At this time it is necessary to install the provided shifter pawl The pawl included with the Builder s Kit is essential to the proper operation of the shift mechanism It was specifically designed to improve fork shifting and operate in conjunction with the new shift drum to provide ease and smoothness of shifting It will be necessary to replace the 7 16 external snap ring and washer that retains the pawl with the ones provided at this time EV STE
13. the shift drum assembly as detailed in Figure 10 making sure that the fork pins are properly riding in the drum Install the provide 1 4 20 x 1 1 4 SHCS along with washers as you would with a stock drum Put a small amount of Blue threadlocker on the ends of the bolts and torque them down in a circular patter 7 9 ft Ibs 84 108 in Ibs PAGE 12 ASSEMBLY BAKER DD6 BUILDERS KIT ASSEMBLY Shifter Pawl Adjustment All models shifter pawl is adjusted in 3rd gear All kits will include a replacement eccentric screw and jam nut for pawl adjustment The eccentric screw must be timed to the shifter pawl so they move on the same axes The directions will be described as looking at the bike from the left side When you turn the eccentric screw clockwise the shifter arm should transverse to the rear of the bike When you turn the screw counterclockwise the arm should move to the front of the bike If this is incorrect the eccentric is off 180 degrees turn the eccentric 72 turn clockwise Now that the eccentric screw and shifter pawl are timed correctly put the transmission in 3rd gear With the transmission in 3rd gear adjust the pawl to have equal free play do not force against return springs front to back on the dowel pins Tighten jam nut now double check shifter pawl adjustment as seen in Figure 11 Reassemble the remaining components of the transmission as you would any stock 5 speed as detailed in the Factory Service Man
14. ual NEUTRAL SWITCH Depending on the year of the motorcycle it may be necessary to replace the neutral switch All OO 06 Softail models along with the 01 06 FLT and 05 models with a black body switch require installation of the neutral switch silver body provided for proper neutral light function A A p A FIGURE 10 PROPER SHIFTER PAWL ADJUSTMENT IN 3RD GEAR k 4 M j V S FIGURE 11 REPLACING THE NEUTRAL SWITCH PAGE 13 ASSEMBLY BAKER DD6 BUILDERS KIT ASSEMBLY PRIMARY CHAIN AND SPROCKET INSTALLATION Provided as part of the DD6 Builder s Kit is a 28 tooth compensating sprocket primary chain and tensioner with hardware with some kits to be assembled as shown in Figure 13 Figure 14 displays the parts included in the kit as follows 1 P N DD6 177 Adjuster Retaining Nut FIGURE 13 2 P N 24091 3 8 16 7 8 Allen Cap Screw P N 006 178 Chain Adjuster Shoe 4 P N 39990 01 Chain Tensioner Some bikes are equipped with the late style chain tensioner and only require a thicker shoe P N DD6 178 Other bikes will require the late model Chain Tensioner P N 39990 01 as well as using the altered bolt and nut that we include in the kit B See Figure 14 and Figure 17 On Some models you will have to clearance the 2 pedastals on the inner primary that the chain inspection cover bolts to In those a
15. ur Factory Service Manual section 7 Mainshaft Countershaft removal Follow gearset removal procedure Next refer to section 7 Main Drive Gear removal and follow removal procedure Be sure to clean the case with Brake Cleaner or another suitable cleaner before continuing with installation If the Builders Kit is going into a new case no preparation is needed CASE CLEARANCE CHECKS The BAKER DD6 hardware is designed to fit in stock H D transmission cases without modification to the case or the six speed components Since most aftermarket cases are styled after the H D equivalent the hardware will fit into aftermarket cases as well This applies in most situations but there are exceptions The internal walls of the cases float around occasionally in H D and aftermarket castings this is not an indication of poor quality but rather is inherent of the casting process Be sure to check for any potential interference before final installation of the gearset Any necessary case modification can be done with a die grinder INSPECT THIS LANDING GEARSET INSTALLATION Special note 2000 06 88B Softail transmissions have a noted shortcoming with the landing that supports the P N 6209 bearing This landing comes from the factory with a very thin wall thickness and cracks in the corner between the landing and the P N 6209 bearing bore Inspect carefully for this situation FIGURE 1 STEP 1 INSTALL THE NEW BEARING 1 Install
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