Output Shaft bolt threads stripped. ( @#$@!) with pic

[Gary04R6]

I just looked on MRCycles and added up all the parts necessary, and it come out to just under $150 with the shaft. If you think you're up to the job, it's not bad and can be done over a weekend. If you don't already have the service manual, download it off here, the thread is stickied at the top of this forum.

I might try to drill out and tap a hole in the shaft just for kicks. I'm not going to lie I'm not 100% certain what gaskets or parts i would need before I break it down. Is there a list anywhere? I know ill need all the outside covers, new oil seal for the shaft, exhaust gasket possibly, but other than that I'm not certain.

I do have the service manual that thing has been really useful. The biggest mystery is after you crack the case is there anything that goes between them during reassembly?

[Eric Baker]

The only thing between the two halves is RTV sealant. With the exhaust gaskets, you're looking at $165, plus the RTV sealant you can get from the local store, and maybe some red and blue loctite.

This is the list of parts you need off the top of my head, it should be everything.





YAMAHA

WASHER, LOCK for 2004 YAMAHA YZF-R6
90215-20004-00



$3.85
Remove

YAMAHA

GASKET, CRANKCASE CO for 2004 YAMAHA YZF-R6
5VX-15451-01-00



$6.53
Remove

YAMAHA

GASKET, CRANKCASE CO for 2004 YAMAHA YZF-R6
5SL-15461-01-00



$8.07
Remove

YAMAHA

GASKET, OIL PUMP COV for 2004 YAMAHA YZF-R6
5SL-15456-01-00



$7.55
Remove

YAMAHA

GASKET, COVER PINION for 2004 YAMAHA YZF-R6
5SL-15463-01-00



$3.83
Remove

YAMAHA

AXLE, DRIVE for 2004 YAMAHA YZF-R6
5SL-17421-00-00



$90.29
Remove

YAMAHA

WASHER, LOCK for 2004 YAMAHA YZF-R6
90215-21290-00



$2.86
Remove

YAMAHA

NUT for 2004 YAMAHA YZF-R6
90179-18667-00


$9.26
Remove

YAMAHA

OIL SEAL,SD-TYPE for 2004 YAMAHA YZF-R6
93102-35423-00


$12.75
Remove

YAMAHA

GASKET,EXST PIPE for 2004 YAMAHA YZF-R6
3YF-14613-01-00
qty 4


$20.04
Remove


Total:

$165.03

[2005R6Rider]

I've actually seen bikes that the sprocket is held on by a retaining clip. I think it was a suzuki

honda uses a bolt threaded into the end of the shaft. you already have a hole started. it wouldn't take much to drill and tap it out for a bolt like that.

MrCycles*Honda*Kawasaki Polaris*Suzuki*Yamaha*Motorcycles ATVS Scooters Utility Vehicles

I was thinking the same thing, you might want to get a left handed tap though to ensure that the bolt isn't going to thread out.

[serpentracer]

I was thinking the same thing, you might want to get a left handed tap though to ensure that the bolt isn't going to thread out.

the nut on them now is a standard thread so that's what you want. it rotates in a counter clockwise direction so the bolt should tighten in a clockwise direction.

[DangerDog]

Don't think it's possible to rethread with a die. It needs a new output shaft, which I know you don't want to hear.

The output shaft is very likely heat treated which will make it damned near impossible to put new threads on it, especially by hand while still attached to the motor and on the bike. Secondly, you've worn off the major diameter of the threads, so there's no material there to actually put a new thread on it. You'd have to move to a smaller nut that still was able to lock down on the sprocket, which would be hit or miss.

Time to split the cases...

[serpentracer]

Don't think it's possible to rethread with a die. It needs a new output shaft, which I know you don't want to hear.

The output shaft is very likely heat treated which will make it damned near impossible to put new threads on it, especially by hand while still attached to the motor and on the bike. Secondly, you've worn off the major diameter of the threads, so there's no material there to actually put a new thread on it. You'd have to move to a smaller nut that still was able to lock down on the sprocket, which would be hit or miss.

Time to split the cases...

we're talking about drilling a hole in the center of the shaft and using a bolt and washer like the honda CBR does. there's already a hole started in the shaft.
he'll have to use some kind of collar/spacer to hold the sprocket in place but it shouldn't take a whole lot of fabrication. a stack of washers would work even.