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I posted this in the for sale section by mistake. Haven't figured out how to remove that post so I'm re-posting it here.
I recently bought a spare set of bevel components for a 250. The gear on the upper shaft has one chipped tooth.I've attached a couple of pictures.
Any opinions as to the usability of this part?
Thanks,
Phil

Could have a bent tooth or altered profile where the metal was torn away. May have bent the shaft or damaged the bearing. You could run it if you verify that the contact with the cam gear is normal. Is the cam gear chipped as well? Matt

Matt,
Only one tooth is damaged. The cam gear is fine and the bearing feels fine. No obvious twist or bending of the shaft.
Perhaps the tooth was damaged by someone locking the gear set with a piece of metal in order to disassemble it but I don't know.
Phil

If you decide to use it, it would be a good idea to take a stone and smooth off all the edges around the break, and inspect the break surfaces to make sure that there are no pieces that might flake off under vibration. A Dremel with a stone would also work.

CZ

If you’ve decided to run it, take some measures to make sure it won’t damage other parts. I’d say assemble the cases with the lower bevel cartridge installed (don’t install the lower bevel drive gear on the crankshaft), fit the cylinder and head with the cam installed but no rocker arms, fit the cam gear and bevel shaft, shim as needed. Then rotate the bevel shaft and see if it binds when the broken tooth is meshed with the cam gear. Since you’re only engaging the upper bevel, you should be able to discern if the broken tooth is “tightening up” relative to how the undamaged teeth feel. If it does tighten up, you might be able to identify the high spots around the break and dress them with a stone until you get a smooth rotation. Matt