Baja Skunkworks 2 Speed Main part Assembly

                                                                  by 2strokers

Disassembly the tranny and swap out your layshaft with the 2 speed layshaft.

And  Reinstall tranny.

**Tranny is not assembled in the picture. It's just a 2speed assembly method. **

Install your stock gear onto the gear carrier with the one-way bearing.

Be sure to use the rubber dampers.

Make sure the layshaft is clean and install the 1st gear and carrier onto the shaft.

Use the small retaining clip that retains this assembly.

Don't forget to use the purple gear spacer !!

 The pinion is fairly straight forward.  The design is such that it tightens during driving.

The 2nd gear pinion has a small raised section on it.

This should face the 1st gear pinion.

On the pinion adaptor use a small bit of grease on the OD that mates to the ID of the 1st gear pinion.

This will make for easier installation and removal.

Install the pinion

Glue the 12x24x6 bearing into the 2nd gear useing red loctite.

Let this dry overnight or stick it in an oven at the lowest temp to get the loctite to setup faster.

Insert the clutch housing into 2nd gear.

Slide the strike pins into the locating features on the housing.

There are four 22mm strike pins and a single 24mm dowel pin for the clutch.

Do not mix these up.        

Make sure that these go all the way into the gear.

They help locate the gear to the body.

Bolt 2nd gear to the clutch housing using the short M4 button head screws.

Install this assembly on to the layshaft.

Install the 24mm dowel pin onto the layshaft

Install the pawls onto the clutch body using the shoulder screws.

Make sure that the head of the shoulder screw is on the outside face of the clutch.

This is the side that does not have a slot.

Use a small dub of grease, on the pin and the holes that the pin gose into.

Without grease, the pin can bind up and snap off the nut.

This is not critical.  If the nut snaps off the pin still functions and

cannot fall out because it is held in place with the clutch cover.

This is one of the redundancies in the design.

Baja Skunkworks said by the update on June 1.

DO NOT RUN THE TWO SPEED WITH THE NUTS ON THE PAWL PIVOT PIN.

For each pawl install a ball, spring, and large set screw.

For an initial setting, screw the set-screws in so that it is 1/2 turn in from flush with the top surface of the clutch.

Make sure to use loctite on this screw.

These set-screw adjust the shift point of the clutch.

Screwing in, increase the RPM shift point and screwing out dose the opposite.

Install the clutch onto the layshaft.  

         Install the smaller set screws that lock the adjustment set screw in place.

Install the clutch cover. Use the countersunk washer and flat head screw to secure the cover to the layshaft.

Use the four M3 screw to secure the cover to the clutch housing.

Make sure you use loctite on all these screws.

Red = Four M3x10mm button head screws.      Blue = Two M3 tiny screws        Yellow = Four M4 x6mm button head screws

It completed it !!

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