OK, as i have posted here previously a couple of years ago, almost exactly as it happened on august bank holiday. my #1 SRX6 5th gear finally let go, first time it's happened to me, now just building my 10th SRX6.
So, casting around, i found that the gears i needed are unobtaneum, and to get the job done at Slipstream would be prohibitively expensive. so my options were, to crack open one of my 2 track bikes, pinch the cluster and flog the rest as rolling chassis & spares. in fact that seemed the only option.
Time passed, lockdown arrived, more time in the workshop thinking & looking ..... hmmm , i have 4 SRX4 engines in various states of repair/knackeredness, i wonder.... just maybe ....
opened up the cases on the engine i had just the bottom end of, (a 5Y7), pulled out the cluster and changer mechanism, got my micrometer out and checked everything against the original ... bloody perfect!... AND the same ratios. so, in it goes, all good so far, then problem #1 appears, clutch basket splines are different, well, thats ok, the 400 engine had a clutch basket in good ish condition, so that's ok, then problem #2 arrives ..... output shaft splines are different and the sprocket fitting is completely different. a search online finds the correct sprocket (wemoto i think), and nut. i also bit the bullet , as i'd managed, hopefully, to effect a repair for pence instead of megabucks, and bought a new oil pump .... ye gods.... silly money these days, but found one for an XT for £79, (instead of the near £200 that local yam dealer was asking for, for a listed SRX version). closed up the engine, (also fitted magnetic sump and oil tank plugs, in case i'd missed a bit of shrapnel) , refitted into chassis, started up in workshop, went though all the gears, seemed to be selecting ok. pumped up the tyres, charged the battery.... by which time the front tyre was flat, so got a new tyre fitted and balanced. took it out for a potter round the lanes... lovely jubbly! .... 2 days ago it went in for it's MOT ... nice ticket with no advisories .... Houston... we're ready for lift off !!
OK, it's stuttering a bit, so today carbs are off and i see i have a knackered inlet manifold. also the engine is a bit vibey.... with a small, but annoying ticking, it is, in all probability that i have got the balance shaft one tooth out of proper alignment.... thats what happens when you let amateurs muck about with things.... BUT... the gearbox is GREAT, so thats the message, there is hope for those who experience 5th gear woes ..... oh... and i do still have 3 400 engines :-)