Countershaft stripped..!

[JxxxOxxxE]

Well, I was out riding my 85' 200x, and after coming off a jump and going back up a hill, it wouldnt move. I looked down, i thought that chain had come off, but saw the countershaft turning, but the sproket not. :doh: Now given that the sproket isnt in perfect shape, from looking at the shaft, i am pretty sure it needs to be replaced. Anyone know best place to get one? servicehonda.com has it for $71.64. I guess I am going to have to do a total teardown all over again to replace it. That sucks. Hopefully I can get away with re-using the gaskets again. I didnt use any sealer, and the bike only has maybe 4 hours on it so far...

[84200s/m]

man that suck i had almost the same thing happen to me the only diff was mine was welded on and it broke so i had it welded back on i am planing on a complete tear down this spring all new gaskets and seals,a ne output shaft ,clutch plates and a tranny bearing

[JxxxOxxxE]

i am thinking about just putting 2 or 3 little tac welds to make it stay until i fell like tearing it completely down again...I wonder if this is a bad idea

[84200s/m]

if u just tack it it wont stay it has to be welded good

[Mobular]

Sounds like a great time to get in there and replace the shaft, and check all the gears, dogs and forks! Couldn't hurt, seeing that you have to tear it down anyways!

[ATC_250SX]

If the sprokets in good shape i would just weld it the shaft is junk anyway you cant hurt it anymore so you mine as well make it last as long as possible. now im sure one of the senior members will say im wrong and its a cheap fix and all and to do it right but, why not its already junt make it work until the sprokets worn right out! just my thoghts.

[JxxxOxxxE]

Originally posted by Mobular
Sounds like a great time to get in there and replace the shaft, and check all the gears, dogs and forks! Couldn't hurt, seeing that you have to tear it down anyways!

It just happens that I was just in this thing. I bought it off a guy with a bad rod bearing, I have rebuilt it, so it has already been gone through.

I think I will end up welding it for a while, then when i finally fell like it, and get everything else restored, i will do it...

[JxxxOxxxE]

someone told me to day that the countershaft is cast iron? thats not right is it? When anyone has welded it on, does it hold pretty good...

[ATC_250SX]

Cast Iron!? my 200 and the 125 motor both have plain old steel shafts, and now to think about it so dose my dirtbike, but maby they would make is cast iron, but i dont see why.

[hrc200x]

Are you sure its the "teeth" on the shaft that are stripped, could be the teeth in the sprocket. I've never heard of this happening, can you post a picture?

[TriZer]

if the shaft's teeth are stripped, weld it, you can always grind it off later. If it's the sprocket, buy the sprocket, they are pretty cheap.

[JxxxOxxxE]

I am about 100% sure that its the shaft, although like I said about, the sproket is far from perfect. I will check it out before i do anything rash. i remember looking at the shaft when i was rebuilding it, and it did look a little bad...

[Fuzzy]

Originally posted by ATC_250SX
now im sure one of the senior members will say im wrong and its a cheap fix and all and to do it right.

Yep i am :D LOL.

Allways do it right if you can.

But because these trikes ride in the dirt. They eat up chains and sprockets pretty fast. So at LEAST!!!! go out and buy a new sprocket to weld on. So that you dont have to grind it off right away. :(

[ATC_250SX]

Well il give it to you there the new sproket could be a good thing, but like you said theres no replcment for the proper fix.

[VAtriker]

do you have a welder and grinder? build up the splines on the shaft (if thats whats wrong) and grind and file them back. run a little water over the shaft seal so it dont get to hot and melt.
CLEAN ALL GREASE AND DRAIN GAS..YOU DONT WANT A FIRE!!

[JxxxOxxxE]

that doesnt sound like a bad idea...

[200x_Basket]

well it is not a bad idea but not the best. i am sure that shaft is heat treated just like the splines on a car axle. the new material will not last long and it may warp the shaft causing greater damage to the rest of the tranny. the best bet is to fix it right. if you dont want to split the case then weld a new sprocket on the shaft. onlu make a couple 1/2" beads and then cool the shaft so that it does not melt the seal.

[JxxxOxxxE]

so no making splines? Hmm...I just dont want to split everything right now again. Where should I ground the welder at? Someone told me if i didnt grind to the shaft, and instead to the frame, that when i welded it on it, some bearings might freeze up??? So on the shaft, or will on the frame be ok?

[84200s/m]

when mine was grounded the guy grounded to the sprocket

mine wont be welded for long i am getting a new gasket kit and an output shaft