Baker Drivetrain Frankentranny Builders Kit

Baker Frankentranny Builder's Kit

BAKER Drivetrain’s 1999 Road King w/Part Numbers: FT106SL (Frankentranny Kit), 478-56CP-U84 (Kicker Cover), 3511-64 (Kick Arm/Pedal Assembly, 475-56P (Oil Spout Assembly), and 5011(Gates Ignition Kit)

Baker Drivetrain Kit Overview

Features

The Frankentranny Builders Kit effectively converts a factory 5-Speed into a 6-Speed overdrive with provisions for a 1936-based 4-Speed kicker. Why did we do this? Because a timeless kicker on a Big Twin looks really cool!

Fitment

• 1990-2006 Big Twin Motorcycles (except 2006 Dyna® )

Tools, Resources, Required Parts

• Touring Models Must Use A True Dual Exhaust System For Proper Fitment
• Factory Service Manual For Your Motorcycle
• Factory Parts Manual For Your Motorcycle
• Common Hand Tools (allens, sockets, hammer / chisel)
• Die Grinder or Files (if transmission case needs to be modified)
• Torque Wrench (with ft. lbs. and in. lbs.)
• Blue Loctite® (242 Removable) or Equivalent
• Red Loctite® (271 Permanent) or Equivalent
• Feeler gauges
• Main Drive Gear & Bearing Service Tools
  • BAKER P/N ToolA-56
  • H-D ® Equivalent P/N 35316A
• Pulley Nut Socket
  • BAKER P/N TOOLD-56
  • H-D ® Equivalent P/N 94660-37B
• Inner Primary Race Service Tool
  • BAKER P/N TOOLB-56
  • H-D ® Equivalent P/N 34902A

Parts Required To Complete Build

• Kicker Cover Kit w/Kicker Gears, See Page 14.
• Kicker Arm w/Pedal, See Page 14.
• Ignition Retrofit Required On Twin Cam Models, See Page 14.
• Fuel Injected Motorcycles Must Be Converted To Carburetor
• 1993-2006 Touring Models Require A BAKER Oil Spout. The Bulky Stock Spout Interferes With The Frankentranny Bearing Door, See Page 14.
• Touring Models Must Use A True Dual Exhaust System For Proper Fitment.

Baker Franketranny Exloded View

Included Parts Detail

Figure 1

Figure 2

Figure 3

Baker Frankentranny Builder's Kit

Dissasembly

1) FOR YOUR SAFETY, DISCONNECT BOTH BATTERY CABLES (FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY).

2) With your bike securely supported on a bike lift or jack, drain the transmission fluid. Refer to your Factory Service Manual for location of your drain plug.

3) Refer to your Factory Service Manual for transmission gearset, main drive gear, and main drive gear bearing removal.

4) Remove your transmission speed sensor from the transmission case.

Case Preperation

The BAKER FrankenTranny Builder Kit hardware is designed to fit in a stock H-D ® and aftermarket transmission cases without modification to the case or Six-Speed components, but there are exceptions. The internal walls of transmission cases float around occasionally, this is not a quality problem, but rather is inherent in the casting process. With that in mind the following steps are a number of checks to make sure that your new builders kit will function and perform flawlessly.

1) Checking for 6th gear (P/N: 60866M) Mainshaft clearance

Place the provided door gasket onto the transmission case. The gasket is going to act like a template. If the meat of the boss around the 5/16-18 screw hole and fork rod boss hole is above or below the profile of the door gasket. Mark the area with a black marker; from roughly the 10 o’clock to 2 o’clock position on the 5/16-18 screw hole boss and the 6 o’clock to 8 o’clock position on the fork rod boss, shown in figure 4. If the meat of the boss is below or the same as the profile of the door gasket proceed to step 2

SHOWN IN RED ARE THE AREAS OF CONCERN FIGURE 4

C. After marking the area of concern in step 1B, remove the door gasket, then remove the case material using a coarse flat file or die grinder. Remove only the marked material roughly a ½” back from the door gasket surface.

2) Checking for Auxiliary Fork Rod bridge clearance.

. The auxiliary fork rod bridge comes installed on the inside of the bearing door shown in figure 5. The bridge functions as the support for the 4th gear counter shaft fork. Using the door gasket as a template again, as in step 1A. If any transmission case material is below the profile of the door gasket, mark with a black marker see figure 6.	SHOWING AUXILIARY FORK ROD FIGURE 5

C. If case material is not below the gasket profile proceed to step 3. Remove the marked material with a coarse round file or die grinder. Remove the material inward (perpendicular to gasket surface) roughly 1-3/8” from the gasket surface.

3) Checking right side pillow block clearance.

Install the shift system on the transmission case. Install the four 1/4-20 SHCS bolts with washers; snug the bolts down evenly working in a circular pattern until all four bolts are tight.	SHOWN IN RED IS AREA OF CONCERN FIGURE 6

B. Any clearance greater than zero is acceptable, figure 7. C. If you are installing this builder’s kit into a Delkron® Softail® case, install the shift system onto the case and mark where the right side pillow block hits. You will have to remove some material as shown in figure 8 using a coarse file or die grinder.

CLEARANCE BETWEEN PILLOW BLOCK AND CASE FIGURE 7

4) Checking top cover fitment.

If you are installing an aftermarket top cover, you will have to check for proper fitment around the shift system. Some grinding on the casting webs might be necessary for correct function of the shift drum. All checks should be made with the shift system installed on the transmission.

Gearset Installation

1) Install the provided main bearing (P/N: 6209) into the case with snap ring (P/N: 1302-334PP), bevel side facing out. Refer to your Factory Service Manual for guidelines and proper tools required.

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, FIGURE 11. WHEN INSTALLING THE NEW BEARING, PRESS IT IN CAREFULLY AND DO NOT CRACK THE LANDING OFF OF THE CASE.

ARROW POINTING TO THE AREA OF CONCERN FIGURE 11

2) Remove the 5th main gear (P/N: 61005M) from the mainshaft on your new gearset by sliding it off the end.

3) Install the 5th main gear into the transmission case referencing your Factory Service Manual for guidelines and proper installation tools.

4) Install the bearing door gasket (P/N: 35652-79B) onto the transmission, making sure the gasket is fully seated on the dowels and is against the case gasket surface.

5) Apply some WD40® or equivalent to the main drive gear seal and the mainshaft on the gearset assembly. Install the gearset by sliding the mainshaft through the main drive gear and slowly pushing the whole trap door / gearset assembly until the case dowels pins contact the dowel holes in the bearing door.

6) Using a rubber mallet tap the side of the bearing door (area over the dowels) on each side slowly walking in the trap door / gearset assembly until its flush and up against the gasket. NEVER HAMMER ON THE BEARINGS TO FULLY SEAT THE BEARING DOOR; THIS WILL CAUSE BEARING FAILURE AND DAMAGE YOUR GEARSET

SHOWING SPEED SENSOR INSTALLED FIGURE 12

7) Install the bottom four 5/16-18 SHCS and washers with Blue Loctite® . Torque the four bottom bolts, starting in the center and working your way out to the sides to 16-18 ft-lbs (200-225 in-lbs). 8) Install the top four 1/4-20 SHCS and washers with Blue Loctite® . Torque the four top bolts, starting in the center and working your way out to the sides to 8-10 ft-lbs (100-120 in-lbs).

AUXILIARY ROD ADJUSTER FIGURE 13

9) In your builders kit we supply a speed sensor plug with O-ring and bolt; install the speed sensor plug on your transmission case. Using WD40® on the O-Ring will aid in installing the plug. Using Blue Loctite® on the stock speed sensor bolt torque to 8-10 ft-lbs (100-120 in-lbs).

10) Install your motorcycle speed sensor on the new bearing door using the provided button head bolt with Blue Loctite® , torque to 8-10 ft-lbs (100-120 in-lbs), figure 12.

SHOWING 1ST GEAR ENGAGED FIGURE 14

SHIFT FORK INSTALLATION

Reference the included parts, figure 1 on page 4 and legend on page 5. You will notice that the 3rd (P/N 102-6F), 2 nd (P/N 101-56E), and 1st (P/N 101-6E) gear forks will ride on the primary fork rod (like your stock 5-Speed). The 4th (P/N 102-6E) gear fork will ride on an auxiliary fork rod connected to the bearing door.

1) Using a 3/32” Allen, back out the auxiliary fork rod turning it counter clockwise, until a little over 3/4" is sticking out of the bearing door (past the side cover gasket surface), figure 13. 2) Install the 1 st (P/N 101-6E) gear mainshaft fork. You must slide the 1st gear away from the bearing door and engage the dog teeth of the adjacent gear (4th) to allow room for the fork to slide into position figure 14.

INSTALLING 4TH GEAR SHIFT FORK FIGURE 15

3) Install the 4th (P/N 102-6E) gear shift fork onto the 4th (P/N 61234C) countershaft gear. While holding the shift fork into position, screw back in the set screw for the auxiliary fork rod until it is flush with the side cover gasket surface, figure 15.

4) Install the 3rd (P/N 102-6F) gear counter shaft and 2nd (101-56E) gear mainshaft forks, reference figure 1 and 16 for correct placement of shift forks. 5) If you did not remove the 1/2-20 fork rod set screw from the left side of the case during removal of your stock gearset do so now. Slide the provided fork rod (P/N 122-64; 6.250” rod length) through the primary side of the transmission making sure you go through all shift forks; 1st mainshaft (P/N 101-6E), 3rd countershaft (P/N 102-6F), and 2nd mainshaft (P/N 101-56E) forks.

SHIFT FORK PLACEMENT FIGURE 16

6) Install the 1/2-20 fork rod set screw with Blue Loctite® ; thread into case until it bottoms out then back off a 1/2 turn. Reinstall your transmission drain plug.

7) Apply a generous amount of transmission oil to the forks and fork rods. With all the forks installed, check to make sure that all forks slide freely on the fork rods by moving them back and forth. If you experience any binding in the 4th gear counter shaft fork, you need to go back and perform a clearance check of the auxiliary fork rod / bridge; located in step 2 of the case preparation.

Shift System Installation

1) Install the shift system onto the transmission; making sure to line up the fork pins with the grooves in the shift drum.

2) Install the four 1/4-20 SHCS bolts with washers; snug the bolts down evenly working in a circular pattern until all four bolts are tight. Be sure to apply Blue Loctite® to the bolts with washers. Snug down then torque to 8-10 ft-lbs (100-120 in-lbs). Thanks to our new fixed spindle drum (PN 124A-OD6-A), shimming of the drum is no longer required as of 09-2014. The drum simply bolts into place.

3) Set the shifter pawl adjustment per your Factory Service Manual found in section 7 under, Shifter Linkage Adjustment. Adjustment should be made in 3 rd gear; measurement must be equal to within .010” between pins, see figure 19. Shift through all gears while spinning the mainshaft to make sure everything is functioning correctly. 4) Install the top cover gasket and top cover with bolts referring to your Factory Service Manual.

SHIFTER PAWL PIN ADJUSTMENT FIGURE 18

Finish Line

1) Install the supplied inner bearing race onto the mainshaft, P/N 34091-85 following your Factory Service Manual and using the Inner Primary Race Service Tool BAKER P/N TOOLB-56 or H-D ® Equivalent P/N 34902A. An optional BAKER High Torque Bearing Kit is available P/N 189-56. The BAKER High Torque Bearing Kit replaces the factory roller bearing and race with a precision honed ball bearing and seal. This will eliminate the possibility of the race moving and potentially causing leaks or damage to the transmission.

2) Install the provided clutch release and actuator rod into the mainshaft.

3) Re-install all primary components, rear belt, sprocket or pulley; that you removed to disassemble the transmission following your Factory Service Manual.

4) Install the kicker cover of your choice, and it’s components per the manufacturer’s instruction sheets.

5) Install your exhaust and double check that all fasteners are tight on the motorcycle and any ancillary parts that you removed to perform this installation are back in their intended place on the motorcycle.

6) Fill the transmission with fluid. The BAKER Frankentranny Builders Kit comes with its own 23 fl-oz bottle of Heavy Duty Platinum Spectro® Transmission Fluid. Once the maiden voyage had been made around the block or down the road. Take the time to double check all fasteners and hydraulic fittings for tightness. Also with the bike as close to level as you can safely get it and the transmission fluid warmed up, double check the level of the fluid. Drain off any excess fluid if the transmission is overly full. Level should be at the bottom of the hole. Re-install the oil level plug with; snug. You are complete….

BAKER OFFERS THE FOLLOWING ANCILLARY PRODUCTS FOR THE FRANKENTRANNY BUILDER’S KIT:

FOR TWIN CAM MODELS, ONE OF THE FOLLOWING IGNITION RETROFIT CHOICES IS REQUIRED FOR FUNCTIONAL KICKER OPERATION.