Wow, that is toast, rigging it in my opinion isn’t smart. You could get a complete used motor for half that cost!
Stripped drive pully/Output shaft
Hey everyone. So I was riding yesterday and started hearing a bad grinding noise. When I pulled in the clutch and shifted into neutral it was still there. I ended up having it towed home and started investigating. Basically the nut that holds the front drive pulley on came loose somehow and the pulley started wiggling off the output shaft and totally ground down the splines on the pulley and output shaft. It's pretty bad... So called a local dealer and they said it would be over $2,000 to fix this the correct way. They have to remove the engine and transmission and open the case just to get the shaft out. So I am going to try and ghetto rig this instead. I am looking for a new pulley... I know a lot of you have swapped out to the 30 tooth instead and was wondering if anyone had the original laying around they would sell/part with. Any help or suggestions on what to do here would be greatly appreciated.
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There are tabs that you must bend, to prevent the nut from loosening, also installing the conical washer properly prevents this from happening
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Wow, sorry!! IMO, there isn't enough teeth left on the shaft to make a new pulley a possibility. If there was at least 50% left, I'd say worth a shot but the way it is now I'd bet they'd shear off the minute you got on it going up a bigger hill... 
One jury rig possibility would be to drill through the whole assembly and use something like a selloc(sp??) pin. That would require really precise drilling best done by a machine shop who more than likely won't touch this. Still, I'd hate to rely on this either since to handle the stress you'd have to drill a good sized hole for a bigger pin and in the process weakening the shaft. If it is a total loss, welding is a possibility but again...
I guess my point is that riding a motorcycle will always have some inherent dangers. I accept those and try to minimize/mitigate them as much as possible. A jury rig fix here would really be a 180 there IMO.
One jury rig possibility would be to drill through the whole assembly and use something like a selloc(sp??) pin. That would require really precise drilling best done by a machine shop who more than likely won't touch this. Still, I'd hate to rely on this either since to handle the stress you'd have to drill a good sized hole for a bigger pin and in the process weakening the shaft. If it is a total loss, welding is a possibility but again...
I guess my point is that riding a motorcycle will always have some inherent dangers. I accept those and try to minimize/mitigate them as much as possible. A jury rig fix here would really be a 180 there IMO.
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