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

**Gary04R6** · 12-24-2011, 06:29 PM

I have a 2004 R6 ( 23,000 mostly street) with some issues with the output shaft. I heard a noise that sounded like a "box of nails" up front near output shaft. I remove the cover to find the retaining nut gone and to add insult to injury, the threads where the nut go are worn off. The only fix i know of is to replace the whole output shaft. Is there anything else that i could do? Would it be easy to just get another engine considering mileage. Also I've included a picture below.

**CephasGT** · 12-24-2011, 06:38 PM

From the pic, that looks machined smooth, not worn off. Has the sprocket worked its way outward on the shaft, obscuring the threads maybe?

**Gary04R6** · 12-24-2011, 06:59 PM

So long story. The sprocket fell of its splines. I made a ridiculous mistake being an idiot, I glided down the hill to my house. Well the front sprocket most have ate into the threads wearing them off. My question is what can i do : ( ?

**CephasGT** · 12-24-2011, 07:06 PM

New motor time, I think.

**Gary04R6** · 12-24-2011, 08:13 PM

Is it possible to use a die to re-thread it?

**Eric Baker** · 12-25-2011, 08:47 AM

I wouldn't trust re-threading something like that. I do have to agree with Cephas though, that looks perfectly machined, not like the threads got ground off by the sprocket. The only options I can think of is to replace the output shaft or the whole motor.

**Gary04R6** · 12-25-2011, 04:31 PM

I posted the question on another forum and alot of them are suggesting to just weld it on. Which would defiantly be the half assed fix.

I've never split an engine case before. I'm not exactly sure what i would be getting myself into. I've dropped engines into jet skis etc. But never need to split a case. Any idea what i would be looking at price wise if i split the case? I'm guessing 100 dollars in gaskets and misc stuff. Not included the output shaft.

**CephasGT** · 12-25-2011, 05:42 PM

The only other time I've seen something similar to this (dude cross-threaded the front sprocket on), they just replaced the motor.

**serpentracer** · 12-25-2011, 08:50 PM

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.

http://www.mrcycles.com/fiche_sectio...007&fveh=12197

**Eric Baker** · 12-26-2011, 08:38 AM

Originally Posted by Gary04R6

I posted the question on another forum and alot of them are suggesting to just weld it on. Which would defiantly be the half assed fix.

I've never split an engine case before. I'm not exactly sure what i would be getting myself into. I've dropped engines into jet skis etc. But never need to split a case. Any idea what i would be looking at price wise if i split the case? I'm guessing 100 dollars in gaskets and misc stuff. Not included the output shaft.

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.