Tim got me a very low mileage gearbox for the Roadstar for less than the price of one of the bad gears. I stopped by today, the heads are on, and the rear cylinder valve train is being assembled. A few more hours, and the motor is going back in.
He replaced everything. Gears, shafts, bearings, shift forks and drum, and all linkages. Valves were in excellent shape, and the cross hatch was visible in the cylinder bores. Ring end gap was perfectly in tolerance.
It sure looks like those dogs were ripped right out of the gears. Only got 2 of them - the 3rd one got swept up off the floor. The chip in the other gear was located, too.
The replacement gears were in his opinion, in perfect condition.
He didn't have to spend a lot for parts, so it's looking like about a $1200 repair. Honestly, what could I buy for $1200? A beat up VStar 650??