250-500cc 09 WR300 6 speed conversion

I'm still having problems fitting the tensioner, the arm hits the pawl rather than the roller. Maybe a pic would help.

Rob,

Is that the top for the 6 speed shift drum or off the 5 speed? Same question for the detent arm?

it's all from the 6 speed. Looks like I need to space it out and use the spring from the 5 speed. I don't see anyway to use the 6 speed spring. The diameter of the case casting is too large for the 6 speed spring to slide over.

I did use the 6 speed bearing which is wider but I don't think that's the problem, the shifter works just fine.

If there's any interest in anyone doing this in the future I'll take the parts fiche and highlight all the parts you need to procure, including the gaskets and seals you need to replace

Yes please.. I bought a 6 speed 360 bottom end a couple years ago to install into my 2007 WR250.. But I've been too busy to do the install..
Also although I am a little nervous about the install (I am a bicycle mechanic by trade).. I am more worried about any extra parts I will need
or suggested to replace and I did not order before starting (gaskets, bearings, seals etc).. Also any special tools I will need to do the install
and do not have (pullers, extractors etc).. Nothing worse than taking something apart and then find out that you need a new part and/or a
special tool to proceed.. Thanks in advance.. Cheers..

When I was setting up mine I called Halls and was told the shaft end clearances should be between .0015" and .025". One of the reasons I wanted to know is that my 5 speed shafts had .020" and .025" clearance when I took it apart and it seemed a bit much. I wanted to tighten up the 6 speed to the lower end of the spec, but because of what shims were available, I ended up around .020+".
It shifts and works really good.

The arm in the picture is a 5 speed arm. The six speed has the roller on the other side, so it is on the outside.

I just looked at the parts fiche, I don't think I have the right arm. Funny thing is the fiche shows the roller on the outside with the curved part of the arm up. Both of these are opposite. I'll post the fiche when i get to the office.

One thing i should mention is that i didn't buy a complete bottom end. All I could find was the shafts, shifter drum, forks and tensioner. So there's a good chance I have a tensioner for another transmission.

6 speed on the left
5 speed on the right

Here are the parts fiche for the 360 and 300

You will be an old man before you get it done. Bring it over to my shop and we will do it together no charge.

I'd jump all over that offer.

Rob, when you get the right arm, your problem should be solved.
You might take a close look at your shift shaft spring. If the coils don't line up, it can cause those related parts to bind.

Thanks Armin.. But I am just way to busy with things.. Last year I didn't even get a chance to get to the Ganaraska (not even once).. Mostly dual sported more locally with the wife..

I promised the guys I will be at the Ganny this year.. And I would much rather ride than wrench.. So realistically it will be next winter (or later) before I will do the 6 speed install..
And by then yes I will be an old man.. Because I will be turning 50 in August..

Don't feel bad, I didn't get around to it until I was 53

Realistically if you have the motor out, knew what you were doing. You could do this in an afternoon

Man if someone came up with a reliable service for doing this I am thinking they would make bank. I am constantl hearing people turned away from the 250/300 for lack of 6 gears. If there was a shop doing it would probably be backlogged gawd knows how long. I know I would pay good money to have it done.

I have my six speed sitting here in a box , trying to decide if I should try to do it or just have a real mechanic do it

I hate losing top end drag races to yz250s and 4t 450s. The 5 speed runs out steam pretty quick.

Actually I have a tag on mine and a 2t is a blast on these AMA dual sport rides, so much in fact a couple of the snobbier clubs even ban 2ts from their rides.

Besides, at 53 I'd rather exercise my brain with a Project like this rather than doing crosswords on the Metro

It's turning into a pricey mod. The good deals on eBay aren't there anymore, I paid about $300 for the transmission, the bottom end gaskets, seals and main bearings were $150 and the top end parts are probably going to be at least $175

Also if you check a lot of the 6 speed parts are no longer available from Husky.

If you are considering doing this I would jump on it now, it's not going to get better

FINISHED !!
And it runs

Full report coming up as soon as I can get out

First impressions riding around the 'hood.... With 15/52 easy cruise at 60mpH and will loft the front wheel with a throttle blip in first.