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XL6

The BAKER™ XL6 is a six-speed overdrive ‘cartridge style’ gearset that converts any existing 1991-2003 Sportster/Buell to a BAKER™ six speed. 2nd through 5th gear ratios are effectively the same as stock, 6th gear is a true overdrive for a 511rpm drop at 75mph.

  • 6061-T6 trap door
  • Complete gearset including shafts and gears, less the 5th (maindrive) gear pair. 5th gear pair from existing 5-speed is re-used with the XL6 installation.
  • Gearset is assembled to the trap door including bearings, thrust washers, and retaining rings.
  • Shift drum and detent plate with optimized geometry. No flimsy retaining clip to hold the detent plate to the drum. Ours is bolted on with an machine screw.
  • Low effort detent spring.
  • Three billet steel shift forks with roller pins and cotter pins.
  • Steel template for accurate case modification.
  • ‘XL6’ engraved derby cover (Kit PN 202 & 203 ONLY).
  • 5 Year limited warranty

Benefits

  • 511rpm drop at 75mph
  • 91-94 Sportster/Buell
  • 95-03 Sportster/Buell
  • 91-03 S&S Dry XL Case & Primary Case Only 

 1st Gear Ratio

  • 2.61 (Standard XL6)
  • 2.52 (Standard XL6 w/ HCR)
  • 2.37 (S-Ratio)
  • 2.29 (S-Ratio w/ HCR)

 BAKER recommends HCR usage for most street applications.

2nd Gear Ratio

  • 2.03 (Recommended for Standard XL6)
  • 1.96 (Recommended for Standard XL6 w/ HCR)
  • 1.88 (Recommended for S-Ratio)
  • 1.81 (Recommended for S-Ratio w/ HCR)

Gearset
Stock gear widths in 1st through 5th were retained and a beefy 6th gear was added. This was accomplished by utilizing an exclusive BAKER dog tooth design that is an industry first for American motorcycles. In using male shift dogs with female dog pockets we are able to slam 6 gears within the allowed envelope. Looking at the S&S cutaway you can see there is no room to waste.

 

Shift Drums
Shift drums have optimized fork pin groove geometry for smoother shifting and the ability to find neutral. Drum detent plate is made out of billet and secured to the drum using a bolt, no more flimsy retaining clip. Choice between a standard or reverse pattern shift system. 

  • Standard Pattern Drum 1-N-2-3-4-5-6
  • Reverse Pattern Drum 6-5-4-3-2-N-1
*Standard pattern is 1-N-2-3-4-5-6. Reverse pattern is 6-5-4-3-2-N-1.

 

XL6 Shift Forks

Forks
Our shift forks are made out of billet for strength,  bores are machined / polished to a 32 micro finish and then we hard chrome plate them for wear resistance.

Gear Ratio Comparison Chart

Gear 91-95 96-upw/HCR* XL6 XL6w/HCR* XL6 ‘S’ XL6 ‘S’w/HCR*
1st 2.78 2.69 2.61 2.52 2.37 2.29
2nd 2.03 1.97 2.03 1.96 1.88 1.81
3rd 1.49 1.43 1.49 1.44 1.49 1.44
4th 1.22 1.18 1.22 1.18 1.22 1.18
5th 1.00 1.00 1.00 1.00 1.00 1.00
6th - - .89 .86 .89 .86

Notes

  • HCR refers to the 5th gear pair (maindrive gear pair) that is standard O.E.M. equipment from 96-up. The HCR 5th gear pair gives a significant noise improvement in 5 or 6-speeds, in all gear positions, over the
  • 91-95 style gear that it replaced. BAKER recommends HCR usage for most street applications. If the 91-95 style gears are used.
  • ‘S’ refers to the S-Ratio option available 

RPM Drop From 5th to 6th w/XL6

MPH RPM in 5th RPM in 6th
RPM Drop
65 3162 2719 433
70 3405 2928 477
75 3648 3137 511
80 3891 3346 545

 

Above data based on a 56/35 primary reduction, 61/27 secondary reduction, and a 25” dia. rear tire 

XL6 Part Numbers and Fitment:

PN Description Fitment
201 XL6 Builder’s Kit 91-94 Sportster/Buell
202 XL6 Builder’s Kit 95-03 Sportster/Buell
203 XL6 Builder’s Kit 91-03 S&S Dry XL case
Primary Case Only

 

S&S XL6 Kit Installed, PN 203

Notes

  • The ‘XL6’ engraved derby cover is only included in PN  202 & 203
  • 5th gear pair is not included in the kits, must be purchased separately
  • Add suffix ‘-S’ to the end of the part number for S-Ratio gears; Example 202-S
  • Kit PN 203 is for S&S Sportster Cases; these cases have a special bearing door configuration. The image on the right shows an XL6 S&S bearing door installed in a S&S case.
  • Add suffix ‘R’ to the end of the part number for Reverse Pattern shift system; Example 202-S-R 

Recommended Upgrades

  • Sportster Aluminum Pulleys
  • Sportster Steel Pulleys
  • Reverse Pattern Shift Systems
  • Buell Chain Conversion Kits

 

BAKER XL6 Fluid Capacity Dry: 44-46 fl-oz
BAKER XL6 Fluid Capacity Wet: 40-42 fl-oz

 

**We recommend a 2.03 2nd gear ratio for the 2.61 1st gear ratio. The 1.96 2nd gear is normally paired with the 2.52 1st gear ratio. The 1.88 2nd gear is recommended to go with the 2.37 1st gear. Lastly, BAKER recommends the 1.81 2nd gear ratio to go with the 2.29 1st gear ratio. If you would like a personalized 2nd, 3rd, 4th, or 6th gear pairing, please contact us through the website chat, email us at info@bakerdrivetrain.com, or call us Monday-Friday 8AM-7PM EST/EDT and Saturday 10AM-3PM EST/EDT at 517-339-3835.

TERM AND CONDITIONS                                                                                         

 

BAKER Drivetrain reserves the right to change prices, terms or policies at any time without notice.

Orders can be pre-paid using Visa, MasterCard, American Express, Discover or PayPal.

All orders not pre-paid will be sent C.O.D. certified check or money order only unless pre-approved for company check acceptance.

Any orders from outside the USA must be pre-paid in US funds via wire transfer; a $30 transfer fee will apply.

Prices shown are F.O.B. Haslett, MI.

 

LIMITED WARRANTY POLICY

 

BAKER™ transmission assemblies, transmission kits, primaries, and oil pans 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. BAKER™ clutches, kicker cover kits, belt drives, F6F kit, reverse systems, covers and accessories are guaranteed to the original purchaser to be free of manufacturing defects in materials and workmanship for a period of 2 years from the date of purchase or up to 24,000 miles - whichever occurs first. 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 a description of the problem. If it is deemed necessary for BAKER™ to make an evaluation to determine whether the transmission assembly or transmission kit or accessory 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™  option, repair or replace the defective part of the assembly. 

 

RETURNS AND EXCHANGES

 

Any merchandise returned for any reason (exchange, credit or modification) must be accompanied by a Return Goods Authorization (RGA) number or it will be refused. Call BAKER™ to obtain this number prior to returning goods for any reason. There is a 15% re-stocking fee for all returned items. BAKER™ is not liable for any shipping charges. 

 

ADDITIONAL WARRANTY PROVISIONS

 

NOTE: Limited warranty does not cover labor or other costs or expenses incidental to the repair and or replacement of BAKER™ products.

 

This warranty does not apply if one or more of the following situations is judged by BAKER™ to be relevant: BAKER™ OEM transmissions; (these are subject to the OEM manufactures warranty only), Improper installation, accident, modification (including but not limited to use of unauthorized parts, transmission oils or lubricants), racing, high performance application, mishandling, misapplication, neglect (including but not limited to improper maintenance), or improper repair. 

 

BAKER™ shall not be liable for any consequential or incidental damages arising out of or in connection with a BAKER™ transmission assembly, transmission kit, component or part. Consequential damages shall include without limitation, loss of use, income or profit, or losses sustained as the result of injury (including death) to any person or loss of or damage to property.

 

BAKER™ transmissions, transmission kits and accessories are designed exclusively for use in American V-Twin motorcycles. BAKER™ shall have no warranty or liability obligation if BAKER™ parts are used in any other application.

 

If it is determined that a BAKER™ product has been disassembled during the warranty period for any reason, this limited warranty will no longer apply unless you were instructed to do so by a BAKER Drivetrain technician for diagnostic purposes.

 

The words H-D®, Softail®, FXR®, Dyna®, FLT®, FLH®, Sportster®, and Buell® are registered trademarks and are for reference only.

 

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