1985 Kick Start Idle Gear

[motojason]

Wondering if anyone has experience using a later model kick starter idle gear in an 85 bottom end? I know the tooth count changed in 86. Thought it might be possible to change the clutch basket, idle gear, and spur gear from an 86 to 88 and get it to work? Has anyone tried this?

Thank you,
Jason
 

[motojason]

Will post some pics over the weekend.

The 85 idler gear (27T) has one broken tooth, but everything else is in usable condition.

Alternate to replacement:
Is it possible to repair a gear? Could it be welded, and the tooth rebuilt and the gear heat treated?
Anyone know of a shop in the US capable of doing that type of work?

Thanks!
jason

[sandblaster]

Hey Jason,
Just to let you know, the one you need - FITS 83-85 KX500 - P/N 59051-1107
I would look on eBay every day.
You might also want to fine a complete engine or a bottom end.

[Motorrad]

What's the tooth count on the new one?   Some times like on transmissions they change tooth count on only one gear.

[motojason]

Yes, 83-85 should be the same (27T) gear, thank you. Have been looking on ebay for months, calling salvage yards, and putting feelers out to the vintage race community. No luck so far. I got out bid on a bottom end that was in MI, but that was in early March and there has been nothing since.  

[motojason]

86-04 Idler gears have 26 teeth.

[sandblaster]

You are correct, they have 26T all the way to 04.
I do have a few newer parts in my junk piles and could get you some measurements.
If you take measurements of what you need and make a small diagram showing what you have measured, I could get some comparison measurements.

[motojason]

Thanks Sandblaster! I am traveling for work this week. I'll get the parts measured and post the info over the weekend when I am back at home.

[sandblaster]

Ok, If I miss your post, shoot me a PM and I'll get you what you need.

[Motorrad]

Take measurements the new one may work with minor modifications

[motojason]

You are correct, they have 26T all the way to 04.
I do have a few newer parts in my junk piles and could get you some measurements.
If you take measurements of what you need and make a small diagram showing what you have measured, I could get some comparison measurements.

Let me know if you have any questions. Appreciate the help!

[sandblaster]

I'll be very busy on Monday so I may not be able to get the measurements until Tuesday.

[motojason]

Great, thanks! I'll check back in mid-week.

[sandblaster]

I would measure your clutch basket as well as the spacing between the kick idler shaft and the clutch trans shaft..

[motojason]

Thank you! There is quite a bit of difference in thickness. I will take some more measurements. Given the near 4mm difference in tooth width I am concerned that even if the shaft centers, and diameters align with the 86+ parts that the offsets and cover clearances might not work out.