Re my original post from 4/3/11 about stripped gears, I got another opinion and had it re-looked at. Different mechanic agrees that the driveshaft (countershaft) is worn, not stripped.  Front pulley teeth are gone completely, but teeth on shaft are rounded on the leading (torque) edge. Teeth are square on the back edge, but the front side of each tooth looks almost like someone tried to grind it into a dull knife edge.  Mech will install front pulley (generously supplied by mpnoffi) but is afraid as soon as one tooth slips, gears will strip again and possibly instantly disable bike at an inopportune time, like making a left turn in an intersection.  Could go forever, but mech seems to think it will happen sooner than later and also recommends complete engine teardown and replacement of shaft and pulley.  Decision time.

it wouldnt be worth your time or effort to replace the shaft yourself and it wouldnt be worth the money to have someone else doing it. If it really comes down to it, part out what you've got and buy a new bike. I dont think the JB weld is even needed at this point. Provide pics if possible. The splines on the shaft would have to be considerably worn to cause any real concern.

JB weld is the only reasonable answer here, IMO... I know thats what Id do if it was mine.

try and she goes till she blows!
nothing to lose, just carry a cellphone and know someone to pick you up in the event it does go out unexpectedly on the road.

Serowbot wrote on 04/09/11 at 10:02:57:

we have report that one member did it and it was holding.
what would I do?
put it together w/o it and torque it up tight.
if it ever fails, it will give you the same warning signs.
won't ever be sudden, in the middle of the road can't go.

The guys have it right,....if you don't hear and feel it slip a spline or 3, it ain't going to leave you stranded.
But having said that, if and when you do hear it slip a spline or 3, it is history,.....or should I say, on very short borrowed time.

Now, if you really don't trust it, and want it to last, that is easy to do,.....just don't utillize the full output torque of the motor,.......in simplier terms, stay off anything but light throttle.

what happens first is you'll hear and feel an odd buzz when you let off the gas and roll

jb weld or not - the enough torque is the key - it's like 90lbs or so on the nut