Stripped counter shaft help?

So my 01 R6 was getting torqued down, and lo and behold the nuts not getting tight.
Been doing some reading and it's been common for them to strip on the old ones.
It's been suggested to weld and grind off spot welds when the time comes. Don't think I wanna do that.
Can a machine shop rethread this?
Or just push it off a cliff?
Thoughts?

 

A new output shaft is ~$150... then the whole splitting of the cases.

Welding a countshaft on would be easier in the short term.

 

The only viable solution is a new bike.

 

with white wheels...

 

Fixerated.

 

I would weld it for now, fix it for real later when you rebuild or motor swap. It pretty worthless without an output shaft sprocket attached, and you damn sure don't want it coming off and venting the case.

 

Time cert or helicoil are both options

 

Helicoil/timesert an external thread?

 

I don't think thats an option. LOL

 

Get a Harley.

 

Electric wouldn't have this problem....wait, never mind.

 

Make it a chopper.

 

Fixed

 

Gross!!! The push it off a cliff would be more entertaining

 

Who's chopper is this?

 

I have this as a backup I guess, but we don't get along well together

 

It can be repaired, but I’d just replace it. Wouldn’t repair on the bike anyway. It would need a preheat before welding imo and the seals may not like that. Proper threads best made on a lathe, and the bike probably won’t fit…

 

Could you drill and tap a hole in the end of the shaft for a bolt/washer? Or is the shaft hardened?

 

And why would we not JB Weld this? Like maybe use the good steel stick stuff but channel your inner Lever and Shervin. Personally I’d give it a few good tack welds and call it a day. Just make sure who ever is welding knows what they are doing. Check it often.
It all honesty, if it were me I’d split the cases and repair it properly. Tough call on an 01 though, but I don’t like riding anything that makes me feel likes it not 100%. I’m sure it’s a hardened shaft but could you not run a die to next smaller size (which may be standard threads) and use that nit accordingly? Don’t have one in front of me to do the math or feasibility.

 

How bad are the threads? A thread file can straighten out some cross threads.

In my experience the counter shaft does not need to be torqued really tight. If you don’t want to weld it, see if you can get a nut slightly snug and then tap over a washer on the flat of a nut or safety wire the nut.