how to Install baker XL6 - 6 speed and Barnett clutch on a Harley Davidsonn Sportster 2003

here is how to install 6 speed Baker drivetrain XL 6 and a Barnett racing clutch, on a sportster from 2003 with 5 original speeds. The sportster is upgraded to 1200, and receives the baker overdrive.
necessary tools are : Dremel 4300 with cut bits and grinder bits, harley clutch disassembly tool, loctite blue and red 262. torch wrenches, and normal tools and sockets. Manual for the bike.
buy the new transmission from Baker: www.bakerdrivetrain.com

[@mikescarlett4704]

Baker Drivetrain as of April 19, 2021 has discontinued these , According to Steve and Michelle as of this morning.... Not enough demand at this time ,, but possibly update if Available again.... Thanks for the Informative Video , Smooth Ride......😎

[@techtips101]

Thanks for commenting and thanks for the info! drive safely.... best regards Rene

[@1966roadking]

Very nice, I have that same bike too, great job!

[@techtips101]

👍 it’s a nice bike and I really hope you enjoy yours as much as I do mine. With 6 speed it cruises excellent and it’s not that difficult to do either. Thank you for watching and commenting. Drive safely. Best regards René

[@Hainero2001]

I would never have done that grinding with the bracket on the bike. You take it off and use a spindle sander to grind it down. It some out smoother and you don't have potential debris left behind in the primary. That was pretty stupid.

[@techtips101]

Thanks for watching and commenting. The bracket is needed to be in place since that is, or was the mold that comes with the new transmission. It’s a part of the spare parts when it arrives and referred to in the manual, which also comes with it, so it’s not a good idea to let it out and grind without that bracket. It actually prevents you from destroying your engine block. Yes I could have used a sander instead, but I would have had a lot more and smaller debris in the engine which I would not have been able to get out, and that could have damaged the bearings as well, plus this would have made me still lying on the floor today trying to sand it. It takes too much time. The bike is driving absolutely perfect and have done that for the last 3 years now. I can only recommend baker transmissions for this kit. It has done exactly what I wanted and have not failed at all yet. You are entitled to your opinion, I don’t think it was stupid to do and I actually like the result. I did use a sander initially, but man it was too much time and work. This works fine. Drive safely out there, take care. Best regards Rene

[@jonnymac8925]

Great job, but I couldn't help notice you didn't soak the clutch plates before installing them. Does the bike lurch forward when you put it in 1st, or does it make some gross noises when you shift? You may also might notice it very hard to get into neutral?

[@techtips101]

Hi Jonny Mac, Thanks for taking the time to comment, and yes I did forget to wet the clutch initially, to overcome the problem its imperative to remove the ignition cables and dry run the gears after assembly, it will then soak in by itself, and run without flaws. I have now been driving it since the video was produced and there is no creepage in first gear what so ever, it is very easy to get in Neutral too. Reason its very easy to get in Neutral is, that Baker also delivers a small tension spring with different strength, and when you install this spring, you will notice its a lot easier to get into neutral and have an absolute great driving experience. Always do a new clutch adjustment as per specifications and this should help you to get rid of these signs if they appear. I have enjoyed the bike on several occasions, and I am very happy with the performance and fuel milage at around 75 mph. The biggest concern, I had, when modifying the bike, was the grinding into the engine itself, the mess it makes inside the transmission etc, so make sure you have some great tools here since it hurts into you soul to make an error here :) I Hope that explains it a little, best regards Rene

[@jonnymac8925]

I don't know how I missed your response but I am glad to hear that it didn't cause you any initial grief. I figured after a bit the plates would soak but I have seen people forget to pre soak the plates and end up scaring themselves when they put it in gear and the bike starts to move even with them holding the clutch in😂 That being said, a man would have to be crazy to not do a clutch adjustment at both the clutch and primary ends, but then again there are lots of crazy people out there, but I don't think you are one of them! I have a rubbermount, so no 6th gear or grinding inside that side of the motor for me!... Notice how I said THAT side of the motor ;)

[@louiewatson9389]

I imagine this would throw your gear indicator off.

[@techtips101]

Thank for commenting :) in this case and on this bike the Baker XL6 does not throw you gear indicator off. The neutral is still the same and indications the same. I elected to go standard 1 down and 5 up, you can program the gearbox as you would like. You could go 1 up and 5 down as well. Bear in mind this is a 2003 Harley and that has only neutral indication. Some of the other Harley models like Road King, will need modifications on the shifter drum - this one does not require that. Some models also have a speedometer problem depending on where your speed is measured, and therefor require a speed calibration, and again this model does not require that, so all in all with the Baker 6 XL6 it is actually not so complicated to install. I have now been driving it for 6 month almost and I love the overdrive. I hope that helps out with your question, merry Christmas .... have a wonderful day and drive safe best regards Rene

[@derekreilly1039]

Did u have to soak the clutch first or does it go in dry

[@techtips101]

Thank you for watching and commenting, I soaked it in overnight before installing it, it’s a little messy but works ok. If you have the ability to soak it - it’s a must. It doesn’t have to be a lot of oil just so the plates gets saturated and absorbes their new environment to gain their strength, so they won’t break when you start the Harley up. I hope that helps, drive safely, best regards Rene

[@bvonroth]

No way I could do that and risk putting so much garbage into my gear case. Did you drop the oil after a period to ensure you cleaned out all the shavings, same as breaking in a motor?

[@techtips101]

Thanks for commenting and watching. Yes I dropped the oil and it runs absolutely just great. I have now changed the oil to a much more expensive gear oil - with an emulsifier that makes it run even better. Would I do this again if I had the chance - yes with no doubt. But for now this has sufficiently contributed to my happiness and I enjoy every trip on it. It’s easy to do - just take your time and don’t rush. Drive safely, best regards Rene

[@michaelshanker9564]

I am still having issues w my baker 6 that I bought 10 years ago. It finally shifts well but the cable at the clutch lever is very loose and was told this is the only way it will run and shift propper. Could the stock cable be to long or the clutch lever effect this?

[@techtips101]

Thanks for watching and commenting, you stock cable should not be loose, the clutch should feel like a new clutch. Sounds like there might have been some difficulties assembling it. First the cable can be adjusted at the mid point, at the primary and at the grip. If that is adjusted correctly it should not be loose. Now inside the primary you can adjust the clutch point too and that is easy as well. However it is important that it is assembled correctly from the start. There are two small ball bearings between the two plates for adjustment make sure they are there. Otherwise you need new plates or balls bearing between them. They are easy to loose, and if they are changed with different type or size you will have problems. The clutch adjustment is done with a screwdriver in the center of the clutch plates. There are lots of videos on KZbin where they will show you, I was thinking of making one too. If these things are corrected you should have a perfectly running bike, just like new. I don’t feel any difference between the two clutches except the Barnett clutch is a hair harder to pull. Everything else should be the same just with an overdrive 6 speed. I hope that helps, drive safely Best regards Rene.

[@michaelshanker9564]

Thanks Oliver I'll send this to the shop it's amazing how long I've had this thing and it hasn't been working properly. These are one of the first ones that came out and I know Baker had issues but it's been enough time that they should be able to iron it out.

[@dreamsuju]

hi, my friend looking this spare part for Sportster 1200XL 1991-2003. may i know where you got this part?

[@techtips101]

Yes of course - I bought at Baker. It’s a 6 speed baker, however I don’t know if they discontinued the gearbox, but the best way to figure it out is to contact them. Company : baker drivetrain. bakerdrivetrain.com/ Hope that helps, Drive safely, best regards Rene

[@dreamsuju]

@@techtips101 yeah already asked baker about this but unfortunately this item has discontinued. do you have intention to sell this item? 😅 (just try my friend’s luck)

[@jamessisson5818]

How much was the new 6 speed?

[@techtips101]

approx 2500 usd, for exact price for your model, you will have to ask Bakerdrivetrain. But I think its well worth. Runs so nice . best regards Rene

[@angello15841]

is it only for sportster until 2003? Or from 2003 to date?

[@techtips101]

Thank you for watching and commenting, no it is for sportsters up to the 6 speed with this specific engine. I am a little unsure of the yearly model where it shifted, but generally it’s a great change from a standard 5 to a standard 5+overdrive=6 speed. It drives extremely well and I am very happy with it. Drive safely Best regards Rene

[@angello15841]

@@techtips101 my sportster is 2017. I think that it does not work for mine :(

[@ZackBadCompany1234]

Do u know if I could make this work on a 2020 iron 1200?

[@techtips101]

Thanks for commenting, I don’t know, however doesn’t it already have 6 speed ? Would be happy to help you. Best regards Rene

[@ZackBadCompany1234]

@@techtips101 no the iron 1200 is only a 5 speed unfortunately

[@techtips101]

@@ZackBadCompany1234 Then check with Baker drivetrain - i am not sure if it will fit. Unfortunately. Best regards Rene

[@RedSkeletone]

Will this fit a 2005 as well?

[@techtips101]

Yes 👍 it will fit a 2005. Enjoy it and take your time it’s important to not being in a rush. Drive safely Best regards Rene

[@jackwhite108]

how much does it help

[@techtips101]

Thanks for commenting - so to answer your question, the bike runs great on long straight trips, fuel efficiency is higher due to lower rpm. The bike runs great like a charm and with the overdrive its great. I can only recommend it. Best regards Rene