5th Gear Confusion HELP HELP PLS

Andy Bax

Andy Bax
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Preston, Lancs UK
I am struggling with a damaged 5th gear from a 1976 XS650C (a gear-dog snapped off). I have three 5th gear cogs which are all machined slightly differently. None of the gears have part numbers written on them. I know about the MikesXS 5th overdrive and its associated problems on the forum, so I don't want to go down that route; I want to retain the original gear ratios. I know the later (1978+) gears are different too.
Has anyone come across the slight differences in the machining of that gear (maybe from different years around 1976) and whether they all can be interchanged without fear of slipping out of gear. I sent photos, measurements etc to Yamaha Support...they politely replied 'bike too old, we don't know and can't help'.
I have owned the bike for 30 years and I need some expert help. I can send the photos etc if required.:confused:
 
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