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Old 12-11-2012, 03:48 AM   #5900
Booze Merchant
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Joined: Sep 2010
Location: I see Drunk People.
Oddometer: 722
Countershaft repair.

I know this will sound WRONG to many, but it does work:

Remove or disconnect battery.

Remove sprocket.

Plug in electric arc welder

Do a very quick bead of weld on the countershaft.

Cool immediately with water to avoid melting the oil seal.

Repeat the above two steps until the worn bits are built up.

Use a dremel, small grinder or needle files to file new splines into the countershaft.

It's a most effective $2 repair.
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