We received a notice before Sturgis that the Baker crew scheduled to set up a 6-Speed Overdrive install tent. They did and installed 17 6-speed gear sets during the week. Talk about a rush. A brother rides his 5-speed to the Badlands and glides home on a 6-speed.
Nothing makes more difference to the load on a Evo or Twin Cam engine than shifting into 6th speed at 75 mph on an interstate. Suddenly you're slipping along as if your rear belt disappeared. So, I went after Baker for an install report. Just recently their crew, Jason Hallman and Evan Edwards from JR Cycle Works in Plymouth, Michigan, flew out to man their H-D 105th Anniversary Baker Tent, and they installed another five 6-speed sets.
“They are a Baker dealer and have the knowledge and skillset to handle it,” Trish Horstman, Baker Marketing manager told me. “We have a close working relationship with them and they're perfect for the job.”
That brings up another important point. You don't need to ride a 1000 miles to an event to set your 5-speed free. Find a reputable Baker dealer near you and they'll handle it, or hell, do it yourself with your bros. We'll cover all the basics here, plus the Baker product comes with an extensive installation manual.
If you like this notion and plan to ride to Myrtle Beach (god forbid) or Biketoberfest (that's cool), Baker, Jason and Evan will be there. Here's the drill. It takes about a ½ day for the install. Plan to deliver you bike early in the morning, then go party for the day. When you return in the afternoon the bike will be completed and you can ride away, no break-in period.
It will be oiled with Spectro Oils, adjusted and ready for the road. The team plans for two installs a day, so sign up early. Here's how Baker describes their DD6:
The BAKER DD6 is the ultimate transmission for serious touring, bagger, Softail, or Dyna riders. The ones who really put the miles on appreciate the silent smoothness with our helical highway gears and direct drive engineering (99 percent efficient over 92 percent stock). All steps have been taken to dampen vibration so you, your motor, and the rest of the bike can go the long haul for years to come.
Owning an American made BAKER DD6 will give you peace of mind in your travels. You’ll know that you have the premium drivetrain transmission that is built to endure. You’ll have comfort in knowing that your investment is also supported passionately by BAKER Drivetrain with our hefty 5-year/50,000 warranty. No worries. Ride on. Now get the hell out there, ride hard and far, and know that you’re in good company with the award-winning DD6 from the drivetrain authority.
Our DD6 is finessed for touring model bikes, especially for the later Twin Cam powertrains, as the DD6 mitigates noise amplified in the hollow space between the motor and the tranny. It is the perfect blend of gear ratio, gear type, noise reduction advancements, shift system technology, bearing upgrades and ease of installation. Since the release of the BAKER DD6 in 2003, there have been thousands of satisfied customers world-wide with American touring Big Twins who will attest that it is the premium transmission of choice.
Components
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.
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
□ Pawl and sprocket spacer seals
□ Top cover and fasteners
□ Clutch release cover & fasteners
□ Clutch release mechanism and push rod hardware
The following parts come with the kit:
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.
5. 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
9. Neutral switch (some models).
10. Replacement chain tensioner pad and hardware (some models).
11. Eccentric adjuster screw
12. Seal 12067B
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 tool requiredThe 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.
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 equiv- alent tool, 34902A.
For removing and installing the 1-7/8 transmission pulley nut, BAKER DRIVETRAIN part number ToolD-56 will be needed. The Harley part number is 94660-37A.
Case Preparation and Gear Set Removal
If the Builder’s Kit is replacing an existing 5-speed, refer to your 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 Builder’s 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.
Gear Set 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.
1. Install 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.
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 Tool A-56 and follow the directions as described in the Factory Service Manual.
INSPECT THIS LANDING
STEP 1: Install the new bearing
STEP 2: Remove the main drive gear.
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.
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.
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.
6. Install the four 5/16-18 x 1-1/4 SHCS (socket head cap screws) along with the washers in the lower four holes in the bearing door. Use a small amount of Blue thread locker on the end of the threads and torque the bolts to 13-16 ft. lbs.(156-192 in.lbs.)
Install the two 1/4-20 x 1 1/14 with washers in the same manner above the dowel pin holes and torque them to 7-9 ft. lbs (84-108 in. lbs).
INSTALLING THe SHIFTER PAWL AND SNAP RING
Watch for proper placement of the shift forks. Fork number 4 is placed on the shift 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.
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.
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.
Install the shift drum assembly as detailed, 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. lbs. (84-108 in. lbs.).
Shifter Pawl Adjustment
All models shifter pawl is adjusted in 3rd gear.
All kit’s 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 1⁄2 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.
Reassemble the remaining components of the transmission as you would any stock 5-speed as detailed in the Factory Service Manual.
Neutral Switch
Depending on the year of the motorcycle, it may be necessary to replace the neutral switch. All ‘00 – ‘06 Softail models along with the ‘01 – ‘06 FlT and ‘05 FXD models , with a black body switch, require installation of the neutral switch, silver body, provided for proper neutral light function.
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).
1. P/N: DD6-177 Adjuster Retaining Nut
2. P/N: 24091 3/8-16 – 7/8 Allen Cap Screw
3. P /N: DD6-178 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.
On Some models you will have to clearance the two pedestals on the inner primary that the chain inspection cover bolts to. In those application situations you will have to heli-coil the outer primary cover for the two bolts that you clearanced. For most older applications you will be able to flip the entire tensioner upside down and that will accomplish the difference required.
We do not recommend using “auto tensioners” from any manufacturer with our DD6 Builders Kit.
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 the following recommended oils.
In Milwaukee the crew used Spectro Oils:
Spectro – 75W 140SPL for the transmission
Spectro Heavy Duty Primary Fluid
Spectro Engine Oil 20-50
Special Orders from Baker
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. 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 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.
Future Installation Events
Myrtle Beach Fall Rally – Oct 1-4 – we set up at Broadway at the Beach.
Biketoberfest: Daytona – Oct 16-19 – we set up at the Speedway
Customers can preschedule their installs – or try on the spot – but time slots fill up fast. Or see your local Baker Parts Dealer.
