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Discussion Starter · #1 ·
I had hoped to mix up my gears in the transmission of my ADV650 build to get the lower 1st, 2nd, & 3rd out of the 500 and still have the better 4th & 5th of the 650 trans.

Then run the 500 output gear to get even lover 1st-3rd. and almost stock 4th/5th.





The specs say the gears will fit on the shafts in the right places without problems.

but the 650 gears are not only thicker, they use a 4 finger engagement dog setup.

4 fingers to match into 4 holes.

the 500 uses 3 fingers to fit into 6 holes. (3 of the 6 at a time.)



I could maybe have worked around the thickness of the gears to move the fifth into the 500 tranny, but not with the different finger count.



Also, the 500 trans input shaft is shorter then the 650, so swapping out the first gear set will not work.



I guess I will now be putting a complete 500 trans into my 650 and trying it out.

If 5th gear isn't Too short, and I still think I want a lower 1st gear, I will try adding the 500 output gear and try it that way a bit.



I remember hearing of someone putting Just the 5th gear from a 650 trans in their 500 a couple years ago.

Does anybody know more about it and what was done to interface the gears/shafts?



I know if you put a complete 650 trans into a 500 you need to grind some room in the case for 2nd gear, but I am using a 650 case, so no clearance problems with the case for me.
 

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Please let me know how swapping a 500 trans into a 650 works out for you. I've been toying with the same idea for my hooligan 650. Wouldn't mind more wheelie-ability. To that end, what is this output gear swap of which you speak? That sounds interesting. Also, what about the clutch basket and crankshaft gear? I'm not sure if the tooth count is different between the 650 and 500, but that might be a quick fix for more acceleration too.



Charles.
 

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The clutch and crank gear mod is something I'm considering for my custom to raise the gearing for less revs when cruising.

Can't see why it wouldn't work the other way round.
 

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Guys,

Look at some of JimL's entries about the transmissions. I think Jim has played with them as much as possible and will know the easiest way to change things.

Ed
 

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Discussion Starter · #6 ·
Please let me know how swapping a 500 trans into a 650 works out for you. I've been toying with the same idea for my hooligan 650. Wouldn't mind more wheelie-ability. To that end, what is this output gear swap of which you speak? That sounds interesting. Also, what about the clutch basket and crankshaft gear? I'm not sure if the tooth count is different between the 650 and 500, but that might be a quick fix for more acceleration too.



Charles.




Same reason I am going to lower gears. need the grunt.



The "Output gear" I am talking about is the crank gear.

The only reason we need the 650 clutch in the "650 swap" is because the 650 uses a two piece clutch gear and a one piece crank gear.

I see no reason at this time why we could use a 500 crank gear on a 650 clutch.

I will know pretty soon. I have to drop the motor to do cam chain tensioner as soon as I get home from Christmas.
 
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