250-500cc 09 WR300 6 speed conversion

Finally plan to get started on this project, it's finally turned wintertime around here.

Here's my first problem:
What is the best way to get the loose needle bearings back in? One of the gears slipped off the 360 layshaft and sent all the needles onto the floor. Do you grease the shaft then slide the gear over them or slide the needles back in through the slots on the shaft, neither one of these solutions is working for me at the moment.
Looking at the parts fiche they show up as part # 800027690 with a qty of 68, they are used in two places so am I safe to assume the each takes 34? Will keep this thread updated with my progress or lack thereof
Thanks for your help

Rob,

Having done exactly what you did the first time I did this, I can sympathize. At least mine didn't make it to the floor. Use a really sticky grease and work all the needles back onto the shaft. Just be patient sliding the gear back over. I always put a zip tie on the shaft end outside the end gear on the 6-speed to keep it from falling off anywhere before you install. You really can't get the number of needle bearings wrong. You will either have enough room for one more or you won't. They shouldn't be ultra tight. One more thing you should do is take your micrometers and measure the total width of your 5 speed lay shaft gear cluster with shims and you now want to match that dimension with the 6 speed. Husky has listed many different width shims for this purpose. you are looking for +or- .005". If you need a shim width and can't find it let me know as I might have one. Your clutch shaft cluster is captured by the clutch and is not adjustable.

Let us know how the "sticky" grease works,
Walt

PS, I use Amsoil GLI 2 all purpose grease for this. Pretty sticky but will allow oil penetration and wash out. An offroad cat grease is really sticky but also will want to inhibit oiling. JFYI

U r the man Walt

Got started on this project today and realized I don't have the correct fly wheel puller. Just to confirm is it a 22m x 1.5 RHT?
Thanks

I will be starting a conversion soon and the puller that BMP set me up with is 22X1.5 RHT.

Steve , that is great news you can install mine too

Since we have Uncle Walt to call in case of trouble, we should be fine.

Thanks guys

All taken apart, ready for reassembly

Something is screwy here. That can't be enough shaft to get a sprocket on

and no, the cases aren't bolted back together yet

It looks about right. I think you are just used to the way the 5 speed shafts stick out.
My shaft sticks out .310" from the spacer.

Mine is .300, certainly looks whacked.

Thanks for the reply

Ok, which one goes where? the one on the right has a B stamped on it

Rob,

You can't get it wrong. If you do it will not shift. Its been 4 years since I have done one so which one goes where is not in my memory any longer or nowhere it can be accessed.

Maybe this will help.

I finally figured it out, if you mix them up neither one fits in the shifter drum right.

On to my next issue.

The tensioner on the shifter just doesn't fit right on the star pawl. I'm using the 360 arm and the 5 speed spring but it looks like I need the fab up a spacer to center it on the pawl. Without one it sits too far inboard and the pawl hits the arm instead of the roller.

I did stick the cases back together and now have all six Gears!!!

How much play should the output shaft have? Not measured it but I'm guessing it's around .1mm

Really appreciate everyone's help

Walt ignore my previous email

You shouldn't need to make any spacers. I had the same problem till I got the arm in right.

Rob,

I think I mentioned it in an e-mail, but you need to make sure you got the o-ring in first when putting the outside spacer on the output shaft. If the o-ring isn't in their it will weep tranny oil.

[quote="Rob578, post: 212695, member: 3199"

How much play should the output shaft have? Not measured it but I'm guessing it's around .1mm

/quote]

.1mm is a little tight.

I think .005" is what Husky wants, so you are ~.001" less than that. My guess is that you are fine. A friend of mine did this about 5 years ago and installed it tight with no play. It was a bit stiff but once it broke in worked ok. He didn't have any shims to adjust. I expect that bike to eventually have problems with the out put shaft case bearing on the drive side.