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Ok, I know this is an old thread, but I'm a noob so I gotta ask - has anybody done this to an '06 yet? Is there a comparable swap? I commute on the bike 5 days a week and would love to improve the 5th gear MPG for those lucky days when I get to hit freeway speeds!
 

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It'll work on an 06 but it's a lot of time and trouble to do just for that. Put it off until you're ready for a complete motor rebuild because you basically have to take the entire motor apart to do it.
 

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A pulley change-out would be much easier to do. Only downside is that it changes your final drive ratio for all gears instead of just 5th.....gonna be a little slower off the line.
 

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I have an '06 as well and am considering doing this mod along with a 31 tooth pulley.
Is there a way to check and make sure yami didn't already "improve" the 5th gear for '06?
Also is there a DIY 5th gear swap page somewhere?
thx
 

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I thought I would add to this post...If you have a newer model, the part numbers listed above don't fit. The shafts have been changed. I have an 06, and it takes part #'s 5vn-17151-10-00 and 5vn-17251-10-00. I am unsure about 05, but 04 and earier takes the nubers above. UPDATE! These part numbers do not fit. I ordered them, got them, and found that the rodie has only three fingers to lock gears, and the warrior has four. I haven't found anything that works for 06 and newer.
 

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You're saying that your machine has four dogs on the fifth gear. You have seen this for yourself??

quote:Originally posted by Ross

I thought I would add to this post...If you have a newer model, the part numbers listed above don't fit. The shafts have been changed. I have an 06, and it takes part #'s 5vn-17151-10-00 and 5vn-17251-10-00. I am unsure about 05, but 04 and earier takes the nubers above. UPDATE! These part numbers do not fit. I ordered them, got them, and found that the rodie has only three fingers to lock gears, and the warrior has four. I haven't found anything that works for 06 and newer.
 

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Thats correct. I just put my motor back together. I have both sets of roadie 5th gears on my bench. Neither will fit my 06.
 

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The 5th gear ratio is 24/30=.80 Overall ratio in 5th gear is 1.53*2.39*.80 = 2.93
One moment: the 5th gear ratio is 30/24 if we lead the torque to the right way. Yes, manual told us 24/30 because gearbox divides turnovers, not multiplies it. That means that on 5th gear every turn of crankshaft became 1.25 on secondary axle of gearbox. Pinion 30T and then 24T gear.

The hole way from crank to wheel

1 * 47/72 * 30/24 * 32/35 * 32/70
or
1 * 47/72 / 0.8 * 32/35 * 32/70

The full gear ratio on 5th gear is 0,341043 wheel's turn for every 1 crankshaft turn. :rolleyes:
 

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One moment: the 5th gear ratio is 30/24 if we lead the torque to the right way. Yes, manual told us 24/30 because gearbox divides turnovers, not multiplies it. That means that on 5th gear every turn of crankshaft became 1.25 on secondary axle of gearbox. Pinion 30T and then 24T gear.

The hole way from crank to wheel

1 * 47/72 * 30/24 * 32/35 * 32/70
or
1 * 47/72 / 0.8 * 32/35 * 32/70

The full gear ratio on 5th gear is 0,341043 wheel's turn for every 1 crankshaft turn. :rolleyes:
My .02 on this subject ;)

 

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Cool movie. It will be nice to have another Warrior back on the road. For 2002 there is a fuel tank hardware recall, the tranny recall, the TPS, and the CPS.

Also, although it should be a recall, the left side stock drybreak needs to be replaced with a 2003-or-newer one or an aftermarket one.

Also its nice to swap-in the 2003-or-newer rear suspension shock which adds rebound control.

These used parts get listed here in the classifieds on occasion.
 
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