250-500cc About to tackle the 6 speed conversion!

I finally found a donor bike (94 250) at a reasonable price to turn the 300 into a 6 speed. I've never split the cases on a bike before but after carefully reading the workshop manual and various post on the conversion, I'm feeling reasonably confident. If anyone who has done this before has anything to add please feel free to chime in, all advice greatly appreciated

Always saved this link incase I ever got the chance to do one day, Hope it helps

http://www.thumpertalk.com/topic/532293-wr-250-5-speed-to-6-speed-swap/

That is all the info I needed to do mine.
Thank you Walt

I'm jealous.

Did husky ever make a 5 speed wide ratio?

Yes, they installed them in the '99-01 WR250. Some of the '02's got them but not all. Would actually be a good application for the WR300. For the 250 5th it is a big jump and you have to really rev it out in 4th before grabbing 5th if you are pulling a hill. Nice top end in 5th though~ 85 mph.

Yes, and let me guess, you have one (5SP WR) on ice?.....

I installed mine after I swapped in the 6 speed. I actually initially bought the WR5speed to swap into my 360 and use the 6 speed for my 250. Pulled the 360 apart and gears impacted the case where it is enlarged for the monster 360 crank. Had to put the 360 back together with its 6 speed and then installed the WR 5speed in my 250 until I found a donor 6 speed.

+1 I would not have even known it was possible if not for your efforts. Thanks man and thank you Bax.
It actually took a while to track the donor bike down. The best I could find was a pretty mangy looking bottom end from a wreckers that had been stripped of everything they could get short of splitting the cases and they wanted $900 I got a whole bike for $450 so I might even be able to make a little back

i got a 250 wr 1999 im rebuiling at moment BOOM love it keep us posted, splitting the cranks is easy just go gental and get a rotor puller these things are tight, also impact driver makita an a 27mm socket to get primary drive bolt off and clutch bolt off.

if you were being cunning you could leave the rotor on and let the crank remain in the right hnd side case. but that is if you didnt have a rotor and you got lucky on wich side bearings decided to come out.

Finally got around to splitting her apart today. Everything inside looks pretty good, except for the needle bearings that went everywhere when I tried to swat a mosquito whilst holding the tranny..Bugger.

grouse avatar man!^

Yeah, you gotta watch out for those bastards, they go everywhere. Make sure you find them all.

The thing that made it really frustrating was that I'd studied all the posts I could on the subject and knew to watch out for the bearings and STILL ended up with that sinking feeling when'd I heard metal tinkling everywhere!
Oh well, I found them all but was considering replacing them anyway, can't hurt right?

The 36 odd that are on the last gear? If theres any play or wear go for it but dont do it just for kicks, unless your replacing the bushes and other bearings down the countershafts too.
Oh the main bearings i assume yur replacing them too?
Dont stress if you cant get skf explorers at a c4 clearance.
I slammed c3 in my 360 an still going strong.
Unless some bearing expert knows why they uses such gash tolerance??? Anyone??
Cus the guys at skf said c3 max rpm is 22k and couldnt tell me why husky went for c4's.

Good effort on transplant blair7

Won't be doing the main bearings, the bike hasn't really been ridden that much since I got it new.I'll post some photos of the tranny a bit later. Looks ok to me but it will be good to see what experienced eyes have to say.