BAKER FRANKENTRANNY BUILDER'S KIT - Baker Drivetrain

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BAKER FRANKENTRANNY BUILDER’S KITV4-39093) Install the 4 th (P/N 102-6E) gear shift fork onto the 4 th (P/N 61234C) countershaft gear. Whileholding the shift fork into position, screw back in the set screw for the auxiliary fork rod until it isflush with the side cover gasket surface, figure 15.4) Install the 3 rd (P/N 102-6F) gear counter shaft and2 nd (101-56E) gear mainshaft forks, reference figure1 and 16 for correct placement of shift forks.5) If you did not remove the 1/2-20 fork rod setscrew from the left side of the case during removalof your stock gearset due so now. Slide the providedfork rod (P/N 122-64; 6.250” rod length) through theprimary side of the transmission making sure you gothrough all shift forks; 1 st mainshaft (P/N 101-6E), 3 rdcountershaft (P/N 102-6F), and 2 nd mainshaft (P/N101-56E) forks.6) Install the 1/2-20 fork rod set screw with BlueLoctite ® ; thread into case until it bottoms out thenback off a 1/2 turn. Reinstall your transmission drainplug.7) Apply a generous amount of transmission oil tothe forks and fork rods. With all the forks installed,check to make sure that all forks slide freely on thefork rods by moving them back and forth. If youexperience any binding in the 4 th gear counter shaftfork, you need to go back and perform a clearancecheck of the auxiliary fork rod / bridge; located instep 2 of the case preparation.4C FORK3C FORK1M FORK2M FORKSHIFT FORK PLACEMENT FIGURE 16INSTALLING DRUM SHIM FIGURE 17SHIFT SYSTEM INSTALLATIONThe shift system comes with 3 shims (one .025”thick and two .020” thick), start by installing the .020”thick shim on the shifter pawl side of the drum,shown in figure 17.1) Install the shift system onto the transmission;making sure to line up the fork pins with the groovesin the shift drum.2) Install the four 1/4-20 SHCS bolts with washers;snug the bolts down evenly working in a circularpattern until all four bolts are tight.CHECKING DRUM END PLAY FIGURE 18NEVER RUN ONE CAP SCREW ALL THE WAY DOWN WITHOUTSEQENTIALLY TIGHTENING THE OTHER THREE AS SPECIFIED;IRREPARABLE DAMAGE WILL RESULT.3) Check shift drum end play by using a feeler gauge as shown in figure 18. Shift drum end playis .002” - .010”.A. Place the feeler gage in between the shift drum shim and pillow block ; holding the drumall the way toward the exhaust side. If the measurement is within the specification listedabove proceed to step 4.(CONTINUED ON NEXT PAGE)PAGE 12 - SHIFT FORK INSTALLATION / SHIFT SYSTEM
BAKER FRANKENTRANNY BUILDER’S KITV4-3909B. If the measurement is greater then .010” remove the shift system and add one of theother shims and reinstall the shift system as specified in step 2. Re-measure the drumend play until the measurement is within the specification listed (.002”-.010”).C. In the unlikely event that the drum end play is less than the lower limit of .002”; whichcould be due to variation in your transmission housing or stack up of the BAKERcomponents, give us a call toll free @ 1-877-640-2004. Please have a set of verniercalipers available to take measurements during your conversation to assist us withdiagnosis over the phone. If we determine that the issue lies with your transmissioncase, we will assist you on how to remedy the problem. If the issue lies with our BAKERcomponents we will ship overnight the replacement hardware necessary to remedy theproblem.4) Now that the shift drum end play is set; removethe four bolts and apply Blue Loctite ® re-install boltswith washers. Snug down as specified in step 2 andthen torque to 8-10 ft-lbs (100-120 in-lbs).5) Set the shifter pawl adjustment per your FactoryService Manual found in section 7 under, ShifterLinkage Adjustment. Adjustment should be made in3 rd gear; measurement must be equal to within .010”between pins, see figure 19. Shift through all gearswhile spinning the mainshaft to make sureeverything is functioning correctly.6) Install the top cover gasket and top cover withbolts referring to your Factory Service Manual.FINISH LINE1) Install the supplied inner bearing race onto the mainshaft, P/N 34091-85 following your FactoryService 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 precisionhoned ball bearing and seal. This will eliminate the possibility of the race moving and potentiallycausing leaks or damage to the transmission.2) Install the provided clutch release and actuator rod into the mainshaft.SHIFTER PAWL PIN ADJUSTMENT FIGURE 193) Re-install all primary components, rear belt, sprocket or pulley; that you removed todisassemble the transmission following your Factory Service Manual.4) Install the kicker cover of your choice, and it’s components per the manufacturer’s instructionsheets.5) Install your exhaust and double check that all fasteners are tight on the motorcycle and anyancillary parts that you removed to perform this installation are back in their intended place on themotorcycle.6) Fill the transmission with fluid. The BAKER Frankentranny Builders Kit comes with its own 23fl-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 todouble check all fasteners and hydraulic fittings for tightness. Also with the bike as close to levelas 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 thehole. Re-install the oil level plug with; snug. You are complete….PAGE 13 - SHIFT SYSTEM / FINISH LINE
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BAKER FRANKENTRANNY BUILDER'S KIT - Baker Drivetrain

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