If you have to do this again use a "bearing mount" product on the splines to help fill the gaps and prevent the movement that causes the loosening.  Use a good solvent to clean the shaft before applying bearing mount.  Here is a link to a Loctite pdf product guide.

http://www.loctite.ph/php/content_data/LT4680.pdf

Scan down the document and you will find information on keyed shafts and others.  Bearing mount is often used to fill in the gaps between worn shafts and hubs or bearings.  The goal is to stop the hammering movement that leads to more trouble.  Unfortunately it doesn't work on large gaps, Loctite says it is only good for a .010" gap but I've seen it used successfully on larger gaps.  Also, other people make this stuff and may have better bearing mount than loctite.  Off hand I can't think of the names of the different manufacturers.

What do you think about my method of tightening it down? Too much?

Jsud04 wrote on 09/29/14 at 07:45:50:


Well....there is no way to know what kind of torque is on it with that method.  I suppose if you didn't break off the stud or strip the threads, it might be OK?  I torque it down to the high end of the allowable range with a torque wrench....but then I am not dealing with a worn shaft yet.

You know what is a bit weird about this???????  Lots of motorcycles have the sprockets loose on the shaft....with only a snap ring or similar keeper to hold the sprocket on the shaft....and they don't wear out.  The Kawasaki KZ750 limited has a very similar pulley to the Savage, and the pulley is held on by a keeper that has splines and fits into a groove, and is then bolted to the outside of the pulley....it acts like a snap ring that can't rotate.  Those shafts must be made of something harder than the Savage is.

Have any folks that converted to chains had problems - the sprocket has much less surface area on the splined shaft?????.

I just ordered some small tubes of Permatex 20297 Bearing Mount for Worn Parts 300 degrees up to .02 gap. I will see how it works when it gets in. I am hoping its safe to ride until it comes it?