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For you guys who have seen both trans in pieces, do you think I can fit 450 gears in my 500?????
 

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Not real sure on this one Robb but I did a comparison on bikebandit and from what I see everything is the same but they dont list the gears on the 500.
 

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I have a TRX400FW transmission out but at this time no TRX450 or 500 transmissions .. I do have a 2005 TRX500 mainshaft that I took a picture of beside a 2002 TRX400FW transmission ..The TRX400 & 450 have the same mainshaft & countershaft ..The spline for the manual clutch is different .. I didn't get a chance to measure the shaft size/length today ..

TRX400 & 500 mainshaft pics..



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Here's a parts picture of a TRX450 ..



PARTS LIST 2004 - TRX450FE - TRANSMISSION (TRX450FE)


1 23211-HN0-670 MAINSHAFT, TRANSMISSION (12T/18T) 84.00 1

2 23212-HA0-000 BUSH (17MM) 12.00 1

3 23214-HA0-000 BUSH A (22MM) 14.04 1

4 23220-HM7-000 COUNTERSHAFT 82.00 1

5 23224-HC4-000 COLLAR, COUNTERSHAFT 9.00 1

6 23411-HN0-770 GEAR, COUNTERSHAFT FIRST (49T) 32.00 1

7 23412-HN0-770 SHIFTER, REVERSE COUNTERSHAFT LOW GEAR 19.00 1

8 23413-HA7-670 COLLAR, SPLINE 18.58 1

9 23414-HA0-000 BUSH, SPLINE (25MM) 15.36 2

10 23431-HN0-770 GEAR, COUNTERSHAFT SECOND (43T) 32.00 1

11 23441-HN0-770 GEAR, MAINSHAFT THIRD (23T) 32.00 1

12 23451-HN0-770 GEAR, COUNTERSHAFT THIRD (37T) 32.00 1

13 23453-HN0-A10 COLLAR, COUNTERSHAFT FOURTH SPLINE 17.60 1

14 23454-HA0-000 BUSH A, SPLINE (25MM) 24.90 1

15 23461-HN0-770 GEAR, MAINSHAFT FOURTH (28T) 32.00 1

16 23471-HN0-770 GEAR, COUNTERSHAFT FOURTH (28T) 32.00 1

17 23481-HN0-770 GEAR, MAINSHAFT FIFTH (33T) 32.00 1

18 23491-HN0-670 GEAR, COUNTERSHAFT FIFTH (28T) 32.00 1

19 23621-HN0-670 GEAR, FINAL DRIVE (20T) 77.00 1

20 23720-HM7-000 GEAR, REVERSE IDLE 131.00 1

21 23730-HC4-000 SHAFT, REVERSE IDLE 18.68 1

22 23732-HA0-000 BUSH, REVERSE IDLE GEAR 18.12 2

23 23751-HN0-770 GEAR, COUNTERSHAFT REVERSE (27T) 45.00 1

24 90402-HA0-000 WASHER, THRUST (14MM) 2.80 1

25 90403-HA7-670 WASHER, THRUST (20MM) 4.00 1

26 90412-HA0-000 WASHER, PLAIN (14MM) 4.66 1

27 90451-HM7-000 WASHER, SPECIAL (20MM) 2.36 1

28 90451-KY1-000 WASHER, SPLINE (22MM) 2.39 1

29 90452-HC4-000 WASHER, THRUST (17MM) 3.00 2

30 90601-329-000 CIRCLIP (OUTER) (22MM) 1.50 1


31 91002-PL0-008 BEARING, BALL (62/22) (TOYO) 16.16 1


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Here's a parts picture of a TRX500 ..



RETURN TO TRX500FM - 2005 PARTS

1 23211-HP0-A00 MAINSHAFT, TRANSMISSION 80.18 1

2 23212-HP0-A00 BUSH (17MM) 5.52 1

3 23214-HA0-000 BUSH A (22MM) 14.04 1

4 23221-HP0-A00 COUNTERSHAFT, TRANSMISSION 76.24 1

5 23224-HP0-A00 COLLAR, COUNTERSHAFT 4.20 1

6 23411-HP0-A00 GEAR, COUNTERSHAFT LOW (55T) 3.36 1

7 23412-HP0-A00 SHIFTER, REVERSE COUNTERSHAFT LOW GEAR 16.78 1

8 23413-HA7-670 COLLAR, SPLINE 18.58 1

9 23414-HA0-000 BUSH, SPLINE (25MM) 15.36 1

10 23431-HP0-A00 GEAR, COUNTERSHAFT SECOND (43T) 40.26 1

11 23441-HP0-A00 GEAR, MAINSHAFT THIRD (23T) 25.72 1

12 23451-HP0-A00 GEAR, COUNTERSHAFT THIRD (37T) 40.26 1

13 23453-HN0-A10 COLLAR, COUNTERSHAFT FOURTH SPLINE 17.60 1

14 23454-HA0-000 BUSH A, SPLINE (25MM) 24.90 1

15 23461-HP0-A00 GEAR, MAINSHAFT FOURTH (28T) 40.26 1

16 23471-HP0-A00 GEAR, COUNTERSHAFT FOURTH (33T) 40.26 1

17 23481-HP0-A00 GEAR, MAINSHAFT FIFTH (33T) 18.22 1

18 23512-MB0-000 COLLAR, SPLINE (25X12.5) 16.22 1

19 23521-HP0-A00 PLATE, BEARING SETTING 2.02 1

20 23621-HP0-A00 GEAR, FINAL DRIVE 83.86 1

21 23721-HP0-A00 GEAR, REVERSE IDLE (15/39T) 32.62 1

22 23731-HB3-000 SHAFT, REVERSE IDLE 13.70 1


23 23751-HP0-A00 GEAR, COUNTERSHAFT REVERSE (28T) 40.26 1

24 75146-750-000 COLLAR, DISTANCE (25MM) 4.77 1

25 90401-HP0-A00 WASHER, THRUST (20MM) 2.60 1

26 90403-HN8-000 WASHER, SPECIAL (17MM) 1.64 1


27 90451-KY1-000 WASHER, SPLINE (22MM) 2.39 1

28 90452-GB4-770 WASHER, THRUST (17MM) 1.26 1

29 90459-357-000 WASHER C, THRUST (25MM) 2.66 1

30 90601-329-000 CIRCLIP (OUTER) (22MM) 1.50 1


31 91002-PL0-008 BEARING, BALL (62/22) (TOYO) 16.16 1

31 91002-PL0-018 BEARING, BALL (62/22) (NACHI) 16.16 1

31 91005-657-008 BEARING, BALL (62/22) (TOYO) 16.16 1

32 91006-HN2-003 BEARING, RADIAL BALL SPECIAL (6203U) 7.50 2


33 95701-06016-00 BOLT, FLANGE (6X16) 0.57 1


34 96100-62040-00 BEARING, RADIAL BALL -6204 7.59 1


35 96100-63050-00 BEARING, RADIAL BALL -6305 10.78 1
 

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WOW! How do you know all of this stuff?
 

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You got that right.
 

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He's a mechanic w/ access to all kinds of manuals, and appariently someone who has too much time on his hands to be able to sit and type all that out
 
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