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Replace transmission output shaft?

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2.6K views 7 replies 5 participants last post by  slorider  
#1 ·
Hey, so first time I changed my front sprocket I undid the nut and the overly strong red loctite the factory uses welded the threads to the bolt and they came off with it. I was left with a completely smooth output shaft (no threads).

I ended up re-tapping the threads to a smaller diameter on the output shaft and getting a new bolt. However 15k mi later the nut has sheared the threads off again (happened while I was riding) and the front sprocket fell off.

Needless to say I NEVER want that to happen again, especially with all the long distance riding I do.

I am pretty mechanically capable, but I have no idea what is entailed in replacing this output shaft. Can anyone point me in the right direction as far as what the procedure would be?

Thanks!
 
#5 ·
Nice find on that engine, Steve. Only 150 miles away. $500 is a good price too. I think a new gasket set alone is more than half that price, not to mention the shaft and labor. Of course replacing the shaft might be a fun project for mechanically inclined, slorider. :naughty:

When I was a kid, my best friend had a Hodak Super Rat. Stripped the counter-shaft and had a guy down the street weld on a new front sprocket. :sbmfacepalm:
 
#6 ·
I've noticed the honda 599, (and presumably some others ), have a slightly different setup. Instead of a large nut on the shaft there is a smaller bolt, like 8 or 10 mm, in the center of the shaft, with a large flat washer to retain the sprocket. I wonder if you could drill and tap the center of the shaft and use that method. Would also need some sort of spacer, as the sv sprocket doesn't sit flush with the end of the shaft.
 
#8 · (Edited)
Interesting idea, there is certainly quite a bit of metal to work with. Another idea I had was to drill a hole laterally and use a cotter pin (along with re-tapping again, hopefully with better results). I am mainly trying to get the most robust fix for the cheapest price. I bought the bike for 1300 so not looking to dump a ton of cash into it. Also I don't plan on ever selling it so keeping it stock isn't an issue.

I am sure I could rebuild it without needing to buy a new engine, but as mentioned I can see all the gaskets adding up (although the thought of taking the engine apart kind of excites me). I'm in no real rush as I have other transportation so I'll think things over and update with the fix.

Thanks!