Baker OD6 Installation Instructions - the official baker drivetrain store
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1. BBAJSER PREMIUM DRIVETRAIN INNOVATIONS FOR AMERICAN MOTORCVCLES INSTALLATION INSTRUCTIONS FOR BIG TWIN SIX SPEED OVERDRIVE BUILDER S KITS amp SERVICE GUIDE FOR BIG TWIN SIX SPEED OVERDRIVE COMPLETE ASSEMBLIES 9804 E SAGINAW HASLETT MI 48840 PHONE 517 339 3835 FAX 517 339 4590 TOLL FREE 1 877 640 2004 OD6 EXPLODED VIEW COMPLETE ASSEMBLY VIEW 1 AL BAKER OD6 INSTALLATION INSTRUCTIONS THE FOLLOWING PARTS ARE INCLUDED AS SHOWN IN OD6 EXPLODED VIEW COMPLETE ASSEMBLY VIEW 1 Number Part Number Qty Description 1 34468 56A 1 Top Cover 2 25C225KCSS P 1 1 4 20 x 2 250 SHCS Bolt 3 25C125KCSS P 4 1 4 20 x 1 250 SHCS Bolt 4 6099SS 5 Washer Top Cover 5 33900 59 1 Neutral Switch 6 34904 86E 1 Gasket Top Cover 7 31F100KCSS P 1 5 16 24 x 1 000 SHCS Bolt 8 33715 855 1 Shift Lever 9 70183 1 7116 14 Nut 10 152 56A 1 Eccentric Screw 11 5 6QEN A 1 Shift Drum Assembly 12 23207 4 1 4 20 x 1 250 SHCS Bolt 13 33001 4 Washer Shift Drum 14 609B 6 Alignment Dowel 15 108 6EP 1 Plug Speed Sensor 16 73753 1 1 4 20 x 625 BHCS Bolt 17 66808 1 O Ring Sensor Plug 18 12067B 1 Seal Main Gear 19 11165A 1 Quad Seal 20 33344 94S 1 Spacer 21 34091 85 1 Bearing Race 22 ki 1 Pullev 23 35211 918 1 Pulley Nut 24 40251 92A 1 Lock Plate 25 23202 2 1 4 20 x 625 BHCS Bolt 26 25C225KCSS P 2 1 4 20 x 2 250 SHCS Bolt 27 25C100KCSS P 2 1 4 20 x 1 000 SHCS Bolt 28 25C125KCSS P 2 1 4 20 x 1 252. duties and risks associated therewith BAKER OD6 INSTALLATION INSTRUCTIONS Figure 1 Auxillary fork Cap screws for pillow blocks shaft w clip 2 cap screws chrome 4th gear C S Right side rod end 3 shift drum shims shift drum right side pillow block amp detent assembly primary fork rod Left side pillow block gearset and trap door assembly ist M S w speedo gear fork hole plug 2nd M S gear fork 3rd C S gear fork gear fork BAKER OD6 INSTALLATION INSTRUCTIONS BAKER OD6 INSTALLATION INSTRUCTIONS BAKER OD6 INSTALLATION INSTRUCTIONS Figure 11 4 MI ls 10 BAKER OD6 INSTALLATION INSTRUCTIONS a 49 SIX SPEED Figure 12 Figure 13 BAKER OD6 INSTALLATION INSTRUCTIONS x L Figure 14 9 25 5 u N o o o a A uv BAKER OD6 INSTALLATION INSTRUCTIONS fasteners
3. side door gasket provided onto the dowel pins of the case This gasket is your template Figure 2 shows the area of concern that has to be checked with the template If the thickness of the boss around the 5 16 18 screw hole is above the profile of the gasket from roughly the 10 o clock to the 2 o clock position the material must be removed This is best accomplished by taking a permanent pen or paint marker and drawing around the gasket as shown in Figure 3 Remove the painted material roughly 1 2 back from the gasket surface of the case A coarse flat file works well CHECK 2 AUXILIARY FORK SHAFT BRIDGE CLEARANCE The auxiliary fork shaft bridge comes installed on the inside of the side door as shown in Figure 4 The fork shaft bridge functions as the support for the 4th C S gear fork shaft Again use the side door gasket provided as your template and place it on the dowels Notice the blue paint dot in the upper right hand corner of the gasket If any aluminum is present below the blue paint dot paint the area 3 8 on either side of the blue dot as shown in Figure 5 and remove the material inward perpendicular to gasket surface roughly 1 3 8 from the gasket surface A large coarse round file works well CHECK 3 RIGHT SIDE PILLOW BLOCK CLEARANCE The right side pillow block roller detent assembly needs to be checked for proper fit to the case The right side of the right pillow block needs to be checked for case cl
4. 0 SHCS Bolt 29 597 56C 1 Side Cover 30 130 56C2 1 Dip Stick 2 Piece 31 66827 1 O Ring Dip Stick 32 25452 87A 1 Inner Ramp 33 18052 1 5 16 24 x 625 Hex Bolt 34 987678 3 3 8 Ball 35 25453 87A 1 Outer Ramp 36 34920 86 1 Coupler 37 68067 1 Snap Ring Ball and Ramp 38 36801 87B 1 Gasket Side Cover 39 10705 01149 1 E Clip Actuator Rod 40 609B l Alignment Dowel 41 TWC411 2 Washer Actuator Rod 42 TC411 1 Bearing Actuator Rod 43 37089 84L 1 Actuator Rod Customer Preference BAKER OD6 INSTALLATION INSTRUCTIONS 006 EXPLODED VIEW COMPLETE ASSEMBLY co B T Mo BAKER OD6 INSTALLATION INSTRUCTIONS THE FOLLOWING PARTS ARE INCLUDED AS SHOWN IN OD6 EXPLODED VIEW COMPLETE ASSEMBLY VIEW 2 Number Part Number Qty Description 1 6209 1 Bearing Main Gear 2 1302 334PP 1 Snap Ring Main Gear 3 BK2526 Bearing Countershaft 4 1400 43PP 1 Snap Ring Shifter Pawl 5 6497HW 1 Washer Shifter Pawl 6 12045 1 Seal Shifter Pawl 7 33114 79 1 Bushing Shifter Pawl 8 25702 1 Plug Fork Rod 9 555 56A 1 Shifter Pawl assembly 10 101 56 1 Fork 2M 11 102 6F 1 Fork 3C 12 102 6E 1 Fork 4C 13 101 6E 1 Fork 1M 14 64273 1 Dowel Door 15 61005M 1 Main Gear 5M 16 26770 1 Dowel Door 5 16 X 1 000 Solid 17 35652 79B 1 Gasket Door 18 204C 56P 1 Case 19 11733A 5 Stud Case 20 112 6E 1 Aux Fork Rod 21 3784C 1 Plug Aux Fork Rod 22 103 6 1 Retaining Plate 23 37141 2 3 4 16 Jam Nut 24 23202 2 1 4 20 x 625 SHCS BO
5. LT 25 51740 001 1 Zero Leak Drain Plug 26 6304 2 Bearing Door 27 25C150KCSS P 2 1 4 20 x 1 500 SHCS BOLT 28 31C150KCSS P 4 5 16 18 x 1 500 SHCS BOLT 29 2 6B 1 Door 30 115 6E 1 Pecker Support Bridge 31 122 6 1 Fork Rod 32 F1409 1 Magnet 33 23205 1 1 4 20 x 1 000 SHCS BOLT 34 See View 3 1 Gear Set Assembly BAKER OD6 INSTALLATION INSTRUCTIONS OD6 EXPLODED VIEW GEARSET VIEW 3 NY SS AN Y 75 BAKER 0 6 INSTALLATION INSTRUCTIONS THE FOLLOWING PARTS ARE INCLUDED AS SHOWN IN OD6 EXPLODED VIEW GEARSET VIEW 3 Number Part Number Qty Description 1 11067 6 Retaining Ring 2 61005C 1 5th Gear Countershaft 3 603M2C 1 2nd Gear Countershaft 4 8876A 5 Bearing 5 6003B 7 Thrust Washer 6 61573C 1 3rd Gear Countershaft 7 61234C 1 4th Gear Countershaft 8 62941C 1 1st Gear Countershaft 9 60866C 1 Countershaft with 6th Gear 10 60000M 1 Mainshaft 11 37088 90 1 Clutch Release Rod 12 60866M 1 6th Gear Mainshaft 13 AS2035 1 Shim Mainshaft 14 62212M 1 2nd Gear Mainshaft 15 603M2C 1 3rd Gear Mainshaft 16 61234M 1 4th Gear Mainshaft 17 62941M 1 1st Gear Mainshaft BAKER OD6 INSTALLATION INSTRUCTIONS APPLICATION AND REQUIRED HARDWARE A Builder s Kit is as the name implies for building a BAKER Six Speed Overdrive Transmission using an existing case housing and peripheral hardware The following 5 speed components are required to complete the task Transmission Housing Pawl and sprocket space
6. e trap door gearset assembly until the case dowel pins contact the dowel holes in the side door A rubber hammer is helpful to tap the side door over the case dowel pins without risking any damage to the chrome plated aluminum side door You may also use a slide hammer with a 1 4 30 tip for this task Install the four 5 16 SHCS socket head cap screws in the lower 4 screw holes and torque them to 13 16 ft Ibs Install the two 1 4 SHCS in the screw holes above each dowel and torque them to 7 9 ft Ibs At this time check the fitment of the auxiliary fork shaft into the fork shaft bridge If the fork shaft slides easily into the fork shaft bridge take no action at this time If the fork shaft does not slide easily into the fork shaft bridge then put the auxiliary fork shaft in your freezer at this time This will make the installation of the shaft much easier when the time comes to install it SHIFT FORK INSTALLATION Figure 1 details the names of the 2 shift forks that are provided with this kit Figure 13 details where these forks belong on the gearset The 3rd C S 2nd M S and 1st M S forks will ride on the primary fork rod like 5 speed The 4th C S fork rides on the auxiliary shaft First install the 1st M S fork You must slide the 1st gear away from the door and engage the dogs of the adjacent gear 4th to allow room for the fork to slide on Figure 12 Next install the 4th C S fork Install the 3rd C S and 2nd M S forks in the pos
7. earance see Figure 6 Any gap greater than zero is acceptable as long as the pillow block detent assembly fits down square over the dowels If you are installing a Six Speed Overdrive into a Delkron Softail case you will have to remove some material as shown in Figure 7 Also check to make sure that some gap exists between the torsion spring and the side of the case is shown in Figure 9 BAKER OD6 INSTALLATION INSTRUCTIONS CHECK 4 PRIMARY FORK ROD BOSS CLEARANCE The boss in which the fork rod slides through must be checked for clearance for the 6th mainshaft gear Once again use the side door gasket as a template for this check Figure 8 shows the area of concern If the thickness of the boss is outside the profile of the gasket in the 6 to 8 o clock position it must be removed A large coarse flat file works best CHECK 5 AFTERMARKET CLUTCH RELEASE AND TOP COVER FIT If you are installing aftermarket clutch release and top covers you should check the fit of these covers onto the side door and over the shift drum respectively ADJUSTMENTS SET UP AND CHECKS The BAKER Six Speed Overdrive has only two adjustments just like the 5 speed The first adjustment required is the shift drum end play which is different than the 5 Speed The second adjustment is the shifter pawl eccentric adjusting screw which is identical to 5 Speed and is performed as one of the last steps in the installation On 2000 up Softail and 2001
8. es come with the P N 8996 main drive gear bearing installed For a new aftermarket case or any used case install a new main drive gear bearing and retaining ring as indicated below Remove the main drive gear 5th M S from the BAKER Six Speed Overdrive gearset trap door assembly by simply sliding it off the mainshaft Install a new main drive gear bearing O E P N 8996 with a tool as mentioned in the special tools section of this manual NEVER install the bearing into the case by applying pressure to the inner race you will destroy the bearing Install a new retaining ring with the bevel facing out Special Note 2000 up 88B Softail transmission cases have a noted defect to the landing that supports the 8996A bearing This landing comes straight from the factory with a very thin wall thickness and cracks in the corner between the landing and the 8996A bearing bore Inspect carefully for this situation When installing the new 8996A bearing press it in carefully and don t crack the landing off of the case Install the main drive gear into the main drive gear bearing using the same special tool Hang the side door gasket onto the case dowel pins and carefully push it down to the seat against the case gasket surface Apply some WD 40 or equivalent 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 whol
9. ikely need to go back and perform clearance check 2 in the Case Clearance Checks section again as outlined in the previous section SHIFT DRUM DETENT SYSTEM PILLOW BLOCK INSTALLATION Install the shift drum assembly as detailed in the Adjustments Set up and Checks section This time however you must be careful to make sure the fork pins are in the grooves in which they belong As mentioned before it is recommended that you tighten down the four cap screws in a circular pattern Monitor closely the pins of the forks relative to the shift drum grooves Application of Loctite 242 to the four cap screws is recommended Re check the shift drum end play Set the adjustment on the shifter pawl adjustment screw per the Factory Service Manual Section 7 SHIFTER LINKAGE adjustment CLUTCH ROD END RIGHT SIDE Transfer the thrust washers 2 thrust bearing and retaining ring from your 5 speed right side rod end to the new rod end that has been provided with the kit Install this rod end on the right side at the end of the mainshaft under the clutch cover CLUTCH RELEASE COVER INSTALLATION Install your desired clutch release cover onto the side door The only note is that two of the screw holes in the side door that receive two clutch cover screws have a threaded depth of 1 2 This means if you are using an O E M style clutch cover you must use the two 1 4 20 x 2 SHCS that are provided or any other SHCS with a 2 length The position
10. itions specified Slide the primary fork rod through the 1st M S fork 3rd C S fork and 2nd M S fork Remove the 1 2 20 set screw from the outside of the side door Retrieve the auxiliary fork shaft from your freezer and install it into the access hole from which the 1 2 20 set screw was removed You will have to drive it into the fork shaft bridge that is bolted to the opposite side of the door While tapping the auxiliary fork shaft through with a brass hammer hold onto the 4th C S gear fork and make sure the fork is posi tioned correctly to receive the auxiliary fork shaft that is simultaneously being driven through Once the head of the auxiliary fork shaft is flush with the outside of the side door you will need to drive it another 1 2 carefully into the door until you definitely feel it seat A spare grade 2 soft bolt works well as a punch to drive the auxiliary fork shaft to seat Put some Loctite 242 on the 1 2 20 set screw and torque it to 2 4 ft lbs tightly torqued you will feel it seat against the head of the auxiliary fork shaft Apply a generous amount of WD 40 or transmission oil to the forks and fork rods BAKER OD6 INSTALLATION INSTRUCTIONS FUNCTION CHECK With the 4 forks and the primary and secondary fork rods installed check to make sure that the forks slide freely on the fork rods by moving them back and forth with your fingers In particular if you experience any binding of the 4th C S fork you most l
11. main drive gear and main drive gear bearing HD 35316A is available through your local Harley Davidson Dealer The equivalent tool TOOLA 56 is available through BAKER DRIVETRAIN For removing and installing the bearing inner race on the transmission mainshaft H D 34902A is required The BAKER DRIVETRAIN equivalent part is TOOLB 56 For removing and installing the 1 7 8 transmission sprocket nut H D 9466 37A is required The BAKER DRIVETRAIN equivalent part is TOOLD 56 BAKER OD6 INSTALLATION INSTRUCTIONS INSTALLATION INSTRUCTIONS CASE PREPARATION GEARSET REMOVAL If the Builder s Kit is replacing refreshing an existing 5 speed refer to your Factory Service Manual Section 7 MAINSHAFT COUNTERSHAFT Removal Follow REMOVAL procedure Next refer to section 7 MAIN DRIVE GEAR removal follow REMOVAL procedure If the Builder s Kit is going into a new case no preparation is required CASE CLEARANCE CHECKS The BAKER Six Speed Overdrive hardware is designed to fit in stock H D cases without modification to the case to Six Speed Components Since most aftermarket cases are styled after the H D equivalent the hardware usually fits in most situations but there are exceptions The internal walls of cases float around occasionally in H D and aftermarket castings This is not an indication of a quality problem but rather this is inherent in the casting process CHECK 1 6TH GEAR MAINSHAFT CLEARANCE Place the
12. nts to is 525 thicker than stock experience shows that 400 should be laterally take out of the exhaust bracket to keep the exhaust pipe in the O E M position Modified brackets are available through BAKER at a cost of 25 if you do not have a hack saw and welder at your disposal DISASSEMBLY In general disassembly of your BAKER Six Speed Overdrive is the reverse of content of the Installation Instructions with only one note to remove the auxiliary fork shaft you will need a slide hammer with a 10 32 threaded tip An alternate method is to use a 2 long 10 32 bolt screw Thread the screw into the auxiliary fork shaft and grab the head of the screw with a set of vise grips Give the vise grips a swift tug to extract the fork rod CUSTOMER SUPPORT For any installation or service questions please contact our technical department at 517 339 3835 DISCLAIMER The words Harley H D and Delkron are registered trademarks and are for reference only Use of the H D model designations and part numbers are for reference only BAKER DRIVETRAIN has no association with and makes no claims against these words trademarks or companies The installation of these parts may void or otherwise adversely affect your factory warranty If 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 obligations
13. r seals Shifter pawl assembly Top cover and fasteners Neutral switch Clutch release cover and fasteners Clutch release mechanism and push rod hardware 1 H D Transmission housings come with the left side bearings installed and in the case of the Softail with transmission mounting plate studs installed These items may have to be purchased separately when using aftermarket cases 2 Since the speed sensor provision for the BAKER Six Speed is in the side door it is not necessary to purchase a transmission case with speed sensor provisions CONTENTS Figure 1 shows an illustration of the contents of the Builder s Kit FORWARD We highly recommend that the BAKER Builder s Kit be installed only by trained and or seasoned mechanics with prior H D 5 speed experience If you have never serviced an H D 5 speed do not attempt this installation project REQUIRED READING Regardless of the skill level or experience of the individual installing 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 for the installation The installation instructions for the BAKER Six Speed will make frequent reference to the Factory Service Manual Any Factory Service Manual from 1990 on will be sufficient SPECIAL TOOLS The only special tools required are tools that would also be required for any 5 speed installation For installing removing the
14. s of these two screw holes are shown in Figure 14 SPEED SENSOR INSTALLATION If you have a transmission case with speed sensor provisions install the dummy plug and screw provided with your Builder s Kit in the case Relocate the speed sensor to the provision in the side door See Figure 14 You may require a speed sensor signal conversion box to correctly calibrate the speedo head The new S amp S units are available through BAKER DRIVETRAIN The new S amp S units are sent to you pre set so there is little or no dial in required after installation FLUID FILL Fluid capacity is 20 24 oz of one of the following recommended oil If available at your local dealer we highly recommend Red Line Heavy Shockproof transmission oil Red Line oil can be purchased directly through Baker Drivetrain If Red Line is not available then one of the following oils can be used Bel Ray 85W140 Spectro 75W140 Torco 85W140 BAKER OD6 INSTALLATION INSTRUCTIONS ANCILLARY ITEMS FLT Builder s Kits come with a modified oil spout because the stock oil spout does not clear the thicker side door The modified oil spout is installed with the 5 16 adapter plate and the two gaskets provided one on each side of the adapter plate for proper fit In addition the FLT style exhaust bracket that bolts to the lower part of the side door using the four 5 16 screw holes in the case may have to be modified Since the surface in which this bracket mou
15. tern as specified above is usually sufficient to overcome this Measure the end play next to the right side pillow block as shown in Figure 11 Place the feeler gage in between the shim and the left side pillow block If measured value is within spec discard the other shims When the end play is set to spec confirm that the drum rotates freely by lifting up the detent lever with one hand and rotating the drum with the other The drum should rotate freely If the drum does not rotate freely even though the end play was measured in spec you must increase the end play This potential situation can happen because the feeler gage only measures the end play at one radial point In the unlikely event the end play is less than the lower limit of 002 this could be due to variation in your housing tolerance stack up of the BAKER hardware or a combination of both Regardless of the cause it needs to be corrected Please call BAKER and have some vernier calipers available to take measurements during your conversation to assist with diagnosis If we determine that the difficulty is with your case we will advise you how to remedy the situation If the difficulty is with our hardware we will ship replacement hardware overnight domestic only to remedy the situation WITH THE PRECEDING CHECKS AND SET UPS OUR OF THE WAY YOU ARE NOW READY TO BEGIN THE INSTALLATION BAKER OD6 INSTALLATION INSTRUCTIONS GEARSET INSTALLATION New O E cas
16. up FLT Dyna models 5 or 6 Speed there is no eccentric adjustment screw so no adjustment is necessary The 5 speed end play is adjusted set up on the detent side right side pillow block In the 5 Speed design axial thrust from the shift drum during shifting is controlled by the right side pillow block only Both pillow blocks left and right side control the axial thrust on the Six Speed Overdrive The shim to properly set up the end play is placed adjacent to the left side pillow block Figure 10 Four shims are provided a 036 030 024 and a 020 shim to set up this clearance end play spec is 005 003 Start by putting the 020 thick shim on the end of the shift drum Place the shift drum pillow block assembly onto the four dowels on top of the case Put the four 1 4 20X1 1 4 cap screws wi washers into the pillow block holes and tighten down the shift drum pillow block assembly squarely Squarely means tighten down the four cap screws one turn each at a time to pull the pillow blocks down over the dowels A circular pattern for tightening the four cap screws works best NEVER RUN ONE CAP SCREW ALL THE WAY DOWN WITHOUT SEQUENTIALLY TIGHTENING THE OTHER THREE AS SPECIFIED ABOVE IRREPARABLE DAMAGE WILL RESULT Most aftermarket cases have oversized pillow block dowels The right side pillow block may be stubborn to make its way over the dowels Tightening down the pillow block hex bolts in a circular pat
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