550 clutch in 500

[gary123]

Loads of chatter across various forums on the internet about this, but can it be done. Has anyone on here done it ? I have everything I need except the pinion gear.
Biggest issue seems to be the shape of the case not making a seal, but I reckon I can sort that.
Before I buy a gear does anyone know if the gear and clutch will mesh correctly in 500 cases.

[Trigger]

Why would you want to try. Different clutch, gear box, crank cases and engine cases 

[Oddjob]

Will they mesh, yes.

Tried to do it back in the 70s but as you say the cases are ever so slightly a different shape and all the oil would just run out.

I can see the attraction, the 500 clutch can be heavy if not set up right, so can the 550 TBH.

My 500 clutch was really really light, everything was well greased and set up perfectly, cable routed and oiled correctly, pivot on the lever greased etc.

I'm also looking at an hydraulic conversion to make it even lighter but it's still in the planning stage.

You need a 550 pinion gear let me know, I should have one.

[gary123]

Why would you want to try. Different clutch, gear box, crank cases and engine cases 

Im missing some vital parts for the 500 but have everything I need for the 550. It also adds a bit of a challenge and as the bike will be far from standard it wont really matter.
If it doesn't work out can always go back.

[gary123]

Will they mesh, yes.

Tried to do it back in the 70s but as you say the cases are ever so slightly a different shape and all the oil would just run out.

I can see the attraction, the 500 clutch can be heavy if not set up right, so can the 550 TBH.

My 500 clutch was really really light, everything was well greased and set up perfectly, cable routed and oiled correctly, pivot on the lever greased etc.

I'm also looking at an hydraulic conversion to make it even lighter but it's still in the planning stage.

You need a 550 pinion gear let me know, I should have one.

Think Ive sorted the case shape issue, Ill put a pic up later.

[gary123]

This is a 500 case and the modified 550 case

[Bryanj]

What are you missing for the 500 people here may have what you need

[gary123]

Im missing everything that is under the left cover. I know its all out there somewhere but just fancy a go at the conversion, if it doesnt work out Ill revert to original.

[Bryanj]

You mean the actuating screw and holder, only other thin is neutral switch(which is same) and clutch pushrod, which you need to fill hole in seal

[gary123]

18,3,4,9,5 and 6 are what I dont have.

[gary123]

I can seal the hole using one for a 550.

[Bryanj]

The ball is a standard ball bearing, the spring is any old spring, i have a nos clamp and seal the other bits are available from dave silver when he has stock.

[Oddjob]

I have some NOS 18 parts, the others I may have, not 100% sure. Finding those now in good nick is getting harder and harder and NOS parts are becoming mighty expensive.

[gary123]

Thank you both, I really appreciate your comments and  may well be getting back to you with tail between legs but for now I want to see if I can go the 550 route.
Ive lots of time so just want to see if it works out.

[Oddjob]

What's the filler in the 550 casing Gary?