Ok. So I bought my '95 halfway through last season. I decided (stupid) to rock out with it the remainder of the season before doing a whole lot to it. Season ended. I am a manager at a CNC shop doing mostly aerospace work, so I decided to take it to my shop. After reading most of the post in this forum, I knew the mods I wanted to execute. I ripped it down to the frame and ordered a boat load of new parts....the fun began. I pulled clutch cover and noticed at 24000 miles I got lucky by a few thousandths. I machined a new cam chain tensioner. Turned out great. (If anyone's interested, I suggest you contact Versey....I don't step on toes). Plugged vacuum and opted for the raptor 660 petcock. K&N Cone filter. Deletion of airbox, and in the midst of making a multi chamber compartment to fit nicely in frame while housing the juice box and wires...perhaps a little stash spot as well and at the same time keeping the side covers (Maybe...I might machine my own style side covers). I used the stock seats....however I ripped about 40% of the foam out and replaced it with gel...then covered them with the saddleman covers. I rebuilt the carb. I bubble gummed it together because I deleted the Jardine pipe with a reverse megaphone.....not that it wasnt running lean to began with. I also got the rattlesnake ceramic wrap for the header. bought new battery. new spark plug. retimed valves. pulled head off and fixed the river of oil coming from the bolt plug. Seat mod. bought fork boots. bought aftermarket turn signals. bought aftermarket headlight. bought aftermarket grips. bought aftermarket pegs. bought aftermarket levers. bought new brakes. Bought VHT primer and VHT paint. Ok ok ok.....you get the idea right? I am sure there is more....thats what I can remember off the top of my head......Ok, so I am at the point of cleaning the motor and polishing. The frame, tank, fenders, and about 6 other small parts are boxed up ready to go down and get powdercoated. I polished a few parts already....today I decided to polish the forks and starter braket. In the process of pulling bracket I decided hell, might as well rip this pully off while I am here.....Underneath was what I can only describe as an uppercut to the face. The darn mainshaft is torn to hell. I don't know if I feel comfortable cracking the case and to the best of my knowledge....there is no other way. So did my dream turned to a boat anchor? Is there another way? How long does she have to live? I am wondering if I can fill the gaps with some carbonated fill by welding? Perhaps even welding every tooth together even for she dont budge. Perhaps some kind of hardener will fill the gaps....like a high power locktite formula. I need you guys on this one......how bad is it? There is alot of play.....

http://p1.bikepics.com/2014%5C01%5C17%5Cbikepics-2633685-320.jpg

I got one like that.
I'm thinking of machining a groove and drilling a hole into the groove from the side of the pulley.  Then filling the groove and essentially all of the gaps with JB weld.

that way if you want to remove the pulley you can take a torch to it.

S-P wrote on 01/17/14 at 18:31:06:



S-P: Please PM me....I am unable to PM for a few more post. I am interested in that bottom end.........wait a min   I gotta admit.....never thought I would say that to another man lol

You perves!...  ...
Okay,.. just work it out between yourselves, and don't tell me about it...
I don't wanna' know...
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PS... to others looking in... I just warned "doubloshoe", in another thread,... about the front pulley nut noise being potentially damaging...
If you hear a clicking/squeaking,.. and  can't find it..
Check that front pulley...
If it is the slightest bit loose, it will eat the shaft splines...
Keep that puppy super snug... (mine kept coming loose when tightened to spec...  I've got it at 130lbs plus now... not sure exactly, I used my impact wrench.  but, it's remained tight for over a year)...(the foldover washer can't be trusted)...
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