baker SbD™ inStallation inStructionS
Contents
1. 7 ASSEMBLY BAKER SBD INSTALLATION Install the front motor pulley and lightly tighten the nut Using a straight edge along the outside face of the pulley and a pair of calipers check to see that the two pulleys are axially located within 030 of each other Use the motor plate as a zero reference for measuring the pulley locations FIGURE 9 FIGURE 9 Motor sprocket shaft shims are supplied with the kit Select the appropriate shim or shims Once the axial pulley loca tion is confirmed remove the motor pulley nut and torque it to 150 ft lbs with red loctite On a bench screw the outer bearing support standoffs and locking nuts as far into the outer support as they will go with blue loctite FIGURE 10 Temporarily install the outer support to the pulleys with 3 flathead screws in each pulley Extend loosen the stand offs until they lightly seat into the motor plate The standoff height is set Remove the outer support from the pulleys PAGE 3 INSTALLATION BAKER SBD INSTALLATION Install the starter pinion cover with e a _ blue loctite on the three flat head eee 0a ae screws and torque them to l Ee ee E oo N 100 in lbs FIGURE 11 Install the clutch throwout bearing assembly with the snap ring provided Adjust the clutch pushrod from the right side Lightly screw in the clutch rod with a 7 32 allen until it stops and back it out 1 3 turn Set the 7 16 20 jam nut and reinstall the clutch adjus2. 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 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 FOR QUESTIONS ORDERS OR SUPPORT TOLL FREE 1 877 640 2004 WWW BAKERDRIVETRAIN COM BAIGER DRI VETRALIN PREMIUM DRIVETRAIN INNOVATIONS FOR AMERICAN MOTORCYCLES PHONE 517 339 3835 FAX 517 339 4590 9804 E SAGINAW HASLETT MI 48840 PAGE 11 DISCLAIMER
3. 2X3 8 16 with 5 16 allen for flange It is not necessary to remove the starter from behind the transmission Let starter lay on back of transmission case during O E primary removal and belt drive installation e Outer primary 14X1 4 20 cap screws 3 16 allen e Motor sprocket nut 1 5 16 socket with impact Set nut and washer aside It will be re used on the belt drive motor pulley Chain adjustment shoe nut 9 16 socket e Remove throwout bearing on clutch with medium size snap ring pliers e Remove clutch nut with 1 3 16 socket and 12 impact gun NOTE lefthand threads clockwise to loosen Remove clutch motor sprocket and chain as a complete assembly FIGURE 6 FIGURE 6 4 Jy a d F P i Pa 7 A O j PAGE 5 PREPARATION BAKER SBD KIT PREPARATION e Remove the 8X5 16 18 hex bolts from the inner primary Bend back locktab wings and use a 12 socket to remove bolts e Remove the 2X5 16 18 cap screws from the outside front of the primary with a 1 allen Now the real prep work begins for installation of the belt drive Loosen just a couple turns the six bolts that hold the transmission to the frame with an 5 8 wrench so the transmission is free to move and align with the new belt drive motor plate Remove the primary o ring from the engine case FIGURE 7 so any water that enters that area can drain out r FIGURE 7 Pa J e p p d a r i e Remove the six small o rings f
4. BAKER SBD INSTALLATION INSTRUCTIONS V1 122706 FEATURES OVERVIEW Stainless Steel pulleys for lifetime durability Big 14mm tooth belt compared to 8mm industry standard Proprietary 2 4 wide belt carries over the slammed in look of the O E Balance Drive Outside bearing support with oversized radial ball bearings 12 plate clutch with 1 5X torque capacity and reduced clutch effort 80 reduction in low speed clutch rattle compared to industry standard FITMENT P N 250 BTD Big Dog 2005 up with 250 size rear tire 1 2 offset powertrain P N 300 BTD Big Dog 2005 up with 300 size rear tire zero offset powertrain No additional hardware is required to complete the BAKER Synchronous Drive installation Blue and red loctite will be required for the installation The transmission fluid may have to be topped off after the installation However its a good idea to go ahead and change the fluid if it has not been done recently PAGE 1 OVERVIEW BAKER SBD INCLUDED PARTS THE FOLLOWING PARTS ARE INCLUDED AS SHOWN IN FIGURE 1 prem 8 Starterpinion cover with fasteners D Outside support Position Jacks Eiren j oo Das KUF 2 iy we a ne a A PE a ex en ae ue vy N TOE nei a a oe a se tele ke i Sirs ar Reece PCA aaa 6 EEE Me a so PAGE 2 INCLUDED PARTS BAKER SBD INCLUDED PARTS THE FOLLOWING PARTS ARE INCLUDED AS SHOWN IN FIGURE 2 FIGURE DESCRIPTION Motor plate with trans
5. ed 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 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
6. h comes off so be sure to recheck the oil level or better yet change the oil in your BAKER transmission at this time Reinstall the starter connect the battery and take it for a test drive If you have any questions or concerns call BAKER tech department PAGE 9 INSTALLATION 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 MI 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 F6F is 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 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 purchas
7. mission spacer plate Outside bearing support w bearings spindles amp pulley covers Clutch assembly with 43 tooth pulley FIGURE 2 at FIGURE 3 FIGURE 4 WW Waid PAGE 3 INCLUDED PARTS BAKER SBD SKILLS KNOWLEDGE amp TOOLS SPECIAL TOOLS No special tools are required to complete the installation However the following common mechanic s tools are necessary to do the job in addition to standard every guy tools FIGURE 5 TORQUE WRENCH 1 2 IMPACT GUN PNEUMATIC OR ELECTRIC 13 6 AND 1 SOCKETS PLASTIC OR RUBBER MALLET REFERENCE MATERIALS A 2005 up Big Dog Service manual should be referred to for removal of the stock wet primary FIGURE 5 PAGE 4 SKILLS KNOWLEDGE amp TOOLS BAKER SBD PREPARATION Please refer to the 2005 up Big Dog service manual for disassembly and removal of the stock primary drive The short version of the disassembly process goes as follows Disconnect the battery Remember ground cable first use a 10mm wrench Shut off the fuel at the tank petcock Drain the primary oil Remove the drain plug with a 3 16 allen Remove the clutch adjust access cover on the drive pulley cover on the right side of the bike The access cover comes off by hand like an oil filter Loosen the clutch rod jam nut and draw the pushrod out an inch or so Remove the following parts from the primary roughly in the following order e Starter 9 16 hex for battery feed and
8. rom the transmission case not required e Leave the one o ring on the snout of the transmission to help center the motor plate during installation e Remove Synchronous belt drive content from shipping box Remove all six flat head screws from both pulley covers Outside bearing support assembly motor sprocket and clutch assembly will be separate e Clean and degrease the motor and transmission areas PAGE 6 PREPARATION BAKER SBD INSTALLATION MOTOR PLATE ASSEMBLY INSTALLATION Install the motor plate assembly onto the engine and transmission FIGURE 8 and loosely tighten the 5X5 16 18 cap screws and 5X5 16 18 hex bolts on the motor and transmission with red loctite using a 4 allen 1 2 socket Note the stainless steel cap screws go on the engine No beer breaks here because the red loctite will set up The 6X7 16 14 hex bolts on the bottom of the transmission can be tightened down now with a 5 8 wrench Lastly torque all of the 5X5 16 18 cap screws and 5X5 16 18 hex bolts to 18 ft lbs with a 14 allen 1 2 socket The motor plate installation is complete This tightening ritual procedure is required because the Big Dog system relies on the snout of the transmis sion to orient the complete drivetrain and no shims under the transmission are required Install the new clutch assembly to the transmission mainshaft the LH clutch nut and washer provided Using red loctite torque the nut to 80 ft lbs f FIGURES maures VOJ PAGE
9. t cover Test for clutch actuation and feel If there is excessive or no free play at the clutch lever make appro priate adjustments at the clutch cable adjuster Install the belt over the pulleys Slowly work it over the two pulleys and move it inboard with a top to bottom rocking motion Use a rubber or plastic mallet to help it on if necessary If it does not go on even with persuasion from the mallet call BAKER tech department Do not force it on Make sure the belt is inboard of the outer pulley surfaces Install the outer bearing support to the motor pulley and lightly install the six attaching screws If the clutch outer bearing support cover will not readily slip into the clutch pulley then start two screws at the bottom and gently pull the bottom of the cover into the clutch pulley If the clutch cover still does not want to slip in the clutch pulley then the spark plugs from the engine should be re moved to allow the clutch to be rotated to walk the pulley cover on just like walking a chain onto a bicycle sprocket With both pulley covers in place install all six flat head screws in each pulley with blue loctite and torque them to 100 in lbs With the bearing support firmly attached to the pulleys install the two long flat head screws through the stand offs and into the motor plate with 100 in lbs of torque and blue loctite Some oil may be lost from the transmission main shaft area you will see it when the original clutc
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