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4 to 5 speed conversion unit 650...what to do #340539
10/30/10 12:34 am
10/30/10 12:34 am
Joined: Jul 2007
Posts: 594
australia
6
649 Offline OP
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649  Offline OP
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australia
Hi...Ive bought a complete righthand shift 5 speed box to put in my 69 TR6....what machining needs doing (sleeve bearing?...does it just need filing out or properly machined...is it just for clearance or is it holding and cetering the bearing?) and what else to watch for...giot a complete box with bothe inner and outer cover and all the camplate plunger bits. Also have choice of 19 or 20t sprocket...any drawbacks on a 20t with a 5 speed?
Pic of what Ive got


1970 tr6r dryframe
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Re: 4 to 5 speed conversion unit 650...what to do [Re: 649] #340558
10/30/10 2:17 am
10/30/10 2:17 am
Joined: Apr 2006
Posts: 1,708
Virginia, USA
SBoyd Offline
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SBoyd  Offline
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Virginia, USA
The hog-out that you have to do is just for clearance and can be done carefully by hand.
This is a very easy conversion, IMO the hardest part being to learn how to index a 5-speed and once you learn that it's easy too.
The outer covers (with the shifter dogs) are the same except that you must use the dogs (pawls?) from the 5-speed. They look similar but are slightly different.

good luck
>>sb


Stop the insanity.
Re: 4 to 5 speed conversion unit 650...what to do [Re: 649] #340566
10/30/10 4:15 am
10/30/10 4:15 am
Joined: Jan 2004
Posts: 3,574
ca, us
D
DMadigan Online content
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Posts: 3,574
ca, us
The machining commonly needed is the shield inside the inner gearbox case at the first gear ball bearing.

Re: 4 to 5 speed conversion unit 650...what to do [Re: 649] #340567
10/30/10 5:05 am
10/30/10 5:05 am
Joined: Jul 2007
Posts: 594
australia
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649 Offline OP
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649  Offline OP
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australia
this comes with both the inner and outer cases from the right shift 5 speed.....

ideas on 20tooth vs 19t sprocket too as it comes with choice of either

also does it matter if you use a gasket on the inner case or not with end float?


1970 tr6r dryframe
Re: 4 to 5 speed conversion unit 650...what to do [Re: 649] #340568
10/30/10 5:24 am
10/30/10 5:24 am
Joined: Jun 2007
Posts: 5,557
Maui Hawaii
HawaiianTiger Online content

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HawaiianTiger  Online Content

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Maui Hawaii
You can go bigger than 20 even. You have to do a bit of work on the inner primary if you want access to it without pulling the mainshaft, though. I think I went as high as 24 on one bike way back. Check end float on layshaft only. Should be at least .005 if memory serves. I never use gaskets here. Not needed. Machine work needed is possible with a die grinder. Precision is not required here.
One four speed part you'll need to retain is the shifter fork shaft as the five speed one is not necked down.
The five speed conversion is very nice as they shift with much more precision and more smoothly than the four speed.
Later five speed gear clusters have fewer problems than the first ones.
Bill


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Re: 4 to 5 speed conversion unit 650...what to do [Re: 649] #340617
10/30/10 3:51 pm
10/30/10 3:51 pm
Joined: Mar 2005
Posts: 10,024
Boston, Massachusetts
J
John Healy Online content

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John Healy  Online Content

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J
Joined: Mar 2005
Posts: 10,024
Boston, Massachusetts
As well as the shield Dave mentions above, you need to clearance the shield behind the high gear bearing to allow the high gear to pass through.

If it was me I would be more worried about replacing the early lay shaft you have with this kit with a later lay shaft. The later shaft's high gear is wider, and thus stronger, and is better physically located as to not be able to slide up against the adjacent gear locking up the transmission. If you are going to use this bike you will be replacing it later if you don't do it now.

New avatar complements of Dave Gilbert (an east coast Dave Madigan) ex-employee and good friend

Last edited by John Healy; 10/30/10 6:08 pm.

Re: 4 to 5 speed conversion unit 650...what to do [Re: 649] #340669
10/30/10 10:00 pm
10/30/10 10:00 pm
Joined: Jul 2007
Posts: 594
australia
6
649 Offline OP
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649  Offline OP
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Posts: 594
australia
I think you scared me off buying this...
The seller was unaware of the prob and has offered a no hassle refund which is great and I appreciate their honesty.
It looked a good deal as it was complete rather than the ususal box of bits...
A new layshaft/gear at around $200 puts it too much $$$ to contemplate and I'd never trust it as is...
Thanks again for priceless advice...
I'll keep looking armed with a bit more knowledge.

Last edited by 649; 10/31/10 12:14 am.

1970 tr6r dryframe
Re: 4 to 5 speed conversion unit 650...what to do [Re: 649] #340796
10/31/10 8:22 pm
10/31/10 8:22 pm
Joined: Mar 2005
Posts: 10,024
Boston, Massachusetts
J
John Healy Online content

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John Healy  Online Content

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J
Joined: Mar 2005
Posts: 10,024
Boston, Massachusetts
Depending upon the price, I would not be scared off! These are seldom found so complete. You should be able to find a used late lay shaft!!


Re: 4 to 5 speed conversion unit 650...what to do [Re: 649] #340812
10/31/10 10:29 pm
10/31/10 10:29 pm
Joined: Jul 2007
Posts: 594
australia
6
649 Offline OP
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649  Offline OP
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Joined: Jul 2007
Posts: 594
australia
it was $750...then add $200 for a layshaft/gears and I'd not be sure of using a secondhand output bearing...


1970 tr6r dryframe

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