Countershaft Spline damage
Sadly the splines on my output shaft have been slowly declining. While I have the capability of dropping the motor and splitting the cases. I really don't want to. Has anyone successfully had the splines built up with weld and then filed down so the sprocket fit, while in the bike? The last sprocket and the one I put on yesterday I used a bearing sleeve retainer compound between the splines and sprocket, and then red loctite on the sprocket nut.
The other idea I have been considering is welding the nut to the sprocket.
The bike has 110,000+ miles and has led a hard life. I have a nicer/newer one sitting next to it but I really prefer riding this one as it tells a story and has a lot of sentimental value.