Hi,
I have recently replaced my clutch basket for my DT175 1976 from ebay and on installing have discovered that the replacement gear on the rear of the basket is 123mm as against my original at 128mm!!
I assume i have bought a different model/year so is it possible to exchange the gear from my original to the replacement basket by drilling out the rivits and re-riviting or is this a specialist tooling firm job??

Could you buy the crank gear to match the clutch for an easy fix. Depends if your clutch is of the right model & if the changes are within that model. Not sure about un-riveting & swapping things around. Sounds like quite a difference in size. Is the kick start gear on the back of it the same size.

It sounds like you might not be in the USA? You were sent the correct part for a USA 1976 as 1976 was the first year 175 with the smaller clutch gear and larger crank gear. If you swap crank gears, you'd also have to swap the tach/oil pump gear.

USA 1976 175 was a crossover year... not only primary gear ratio changed but input shaft to trans is smaller as well. Other parts are "1976 only" too.

It would be prudent to check your engine VIN and identify exactly what you have and try to compare parts lists to the US models to make sure you get the right parts.

The good news is the earlier basket with the larger gear is much easier to find than the one year only 1976 part.

You should be able to find casting numbers in your old part and the one you just received... that can help identify and pictures would help us help you.

That's something i'd not considered. So different oil pump speed, then did they change the worm drive & bits in the pump to compensate for speed difference. Or wouldn't it be 'that' different to really matter.

Both plastic gears and tach drive are all different. Pump is too but probably not "that" different that it wouldn't be okay.

Each motor has gears, fitting to the bore distance of the crankcase. There are hand grooved numbers on the gears, so better to re-use them and fix a new basket on the old gear with rivets. I posted some time ago, how to
yamaha-enduros.com/index.php/forums/gene...-gear-drive-possible
Regards Guido

Mark,
My sincere apologies for not answering earlier but i have been away and also working so Forum got forgotten about!!
Please tell me where i can track down a larger gear basket from since i bought the smaller one from Germany expecting it to be 128mm. And yes you are correct i'm in the UK not USA. I will look at the engine number which is* 1G1-100182* but not sure if that was an American export or UK import originally.
Appreciate your input, please continue.

Apologies for late reply but the oil pump gear makes no difference now since the bike is running on 50/1 premix after the pump was removed.

1G1 is not a US model. I will look tonight for your answer.... huge short cut would be knowing if your crank gear is "splined" or "keyed" to the crankshaft. (My guess is keyed)

Thanks Mark for more info, i will look when i have opportunity as to whether its splined or keyed and come back to you.!