1984 WR 500 CLUTHC GEAR

[RUF]

Hi guys.
Am working around a 1984 WR 500 for another project and I found a bad surprise about the cluthc.
4 nuts and bolts between the two parts of clutch gear were missing ( all the parts were on bottom of case ) and the small gear is in very bad conditions.
I guess the best is replacing it but before doing that I wish you guys give me your suggestions.
There is a number on back of gear: 272.
Thanks for any help.

 

[fran...k.]

The part about the bolts and nuts would be a suprise but the condition of that gear is to be expected. Unless you run it for a while change the oil and nothing is on the magnet.

I am not sure exactly where but somewhere in the 1984-1985 era they changed the pitch and perhaps the number of teeth on that small gear, the intermediate gear and the starter gear had to be changed to match. It also appears somewhere in the 1987-88 era I think it is the intrmediate gear got full width instead of champhered on a corner. The later version was somewhat better on that gear at least I think but the hardening of the starter gear where the needle bearings go must have been omitted or not done right. I have a later replacement starter gear and it doesn't have the lightening holes perhaps it is better I don't know yet probably never will. Can't say what has been reproduced and if they are any better on that double gear you pictured. That is about all I can add.

 

[GaryM]

The part about the bolts and nuts would be a suprise but the condition of that gear is to be expected. Unless you run it for a while change the oil and nothing is on the magnet.

I am not sure exactly where but somewhere in the 1984-1985 era they changed the pitch and perhaps the number of teeth on that small gear, the intermediate gear and the starter gear had to be changed to match. It also appears somewhere in the 1987-88 era I think it is the intrmediate gear got full width instead of champhered on a corner. The later version was somewhat better on that gear at least I think but the hardening of the starter gear where the needle bearings go must have been omitted or not done right. I have a later replacement starter gear and it doesn't have the lightening holes perhaps it is better I don't know yet probably never will. Can't say what has been reproduced and if they are any better on that double gear you pictured. That is about all I can add.

I just blew a clutch gear and idle gear at Unadilla - what timing. It was an 886 - thought it would last longer ! They had the first update with the 272 gear above in 84 this was a in between year for this gear and used this year on the WR. XC still used 886s and the CR used the new 076 one piece hub.

In 1985 they introduced the 427 with the big teeth for the idle gear that matched the 076. it still used the same primary gear. I have a couple 427s here but dang did not install yet. Bike is not back yet from NY yet to inspect further.
Oh their is another gear introduced that year but have not seen one in person. It was a 426 number i believed it used the same number of teeth the 076 gear used and the 075 primary gear.