250-500cc 360 6-speed transmission in WR300 - does this look OK to you?

Hi all,

I bought a 1992 WXC360 transmission and installed it in my 2010 WR300. Everything fits and seems to work OK except I'm a little concerned about 6th gear on the main shaft. There is a LOT of slack between the gear and the shaft. I posted a video of it here:


View: http://www.youtube.com/watch?v=5KELP-SdDrQ


The gear can move about 0.1 inches up and down on the shaft. This is the first time I've split the cases on a motorcycle, so I'm not sure what to expect but that seems a little excessive to me. Is this normal? I see a little bit of wear on the splines of the shaft near the gear, but nothing crazy.

Any comments and advice would be greatly appreciated.

Thanks!

Scott

if you look at the gear it probably has no internal splines which would mean it needs to spin on the shaft, typically it's either a bearing on a smooth shaft or a bushing on a splined shaft, seems the gear set was not complete

That's a little excessive. I just installed one myself and it had nothing like that. If memory serves me correct, that is 6th gear and it is free on the shaft and locks into the 3rd / 4th gear set when engaged. I would pull the gear and look at the I.D. before you go any further. I think it should have the same I.D. as 5th gear on the other end of the shaft, which I believe also floats.

If you can't get a new gear, you should be able to have that one re-bushed.

What MOTOHEAD said.
Too much play.

That gear rides on loose needle bearings on the shaft. I believe there are 34 of them, you may be missing a few or all of them. Part # 800027690. I have had the gear slide off of the end before and that allows 6th gear to slide over and the rollers fall out.

that was what my post was about
so it must be a smooth shaft with bearings for isolation of the gear
when a gear (floats) over splined shafts they use a bushing for isolation

Yup, I remember now, the 360 I got the trans from had been apart and put back together without all the needles where they were supposed to be.
34 sounds about right.
PS-one needle was in a nitch in the bottom of the case before I pulled the shafts out.

Yeah, just looked it up in part manual. 34 rollers in it and second gear on the other end of the shaft.

Didn't realize there were needles bearing in them. Just assumed they were bushed.

If you have ridden it you might be feeling some love?

Yeah, I rode it and I love it.

This is my second 250 6 speed.

You guys ROCK! The previous owner split the cases, then put them back together before sending them to me. He likely didn't notice the (golden?) shower of needle bearings spilling out of the 6th speed gear. I'm off to Tasky's to order some first thing in the morning.

Thanks!

Scott