suzuki gs1000 st

[05Astro]

If the splines are worn as bad as they look, the new sprocket won't stay tight no matter what you do.

[storm 64]

Excellent idea MacGyver.👍 Another tip, do the job on a Sunday afternoon right after you get home from church.☺ Also you might try a American thread. The next size under 20mm is 7/8-14 Another concern is the shaft being so hard that the die can't cut it. However, Chuck probably has the right idea. Split the cases and replace the output shaft all together. Hopefully the other nuts and bolts on your motorcycle are not all rooted. Some home mechanics can really tear up a motorcycle. Good luck 👍

[fastbysuzuki]

Put a 2-3 mm chamfer on the end of the shaft.
Find a die like this one http://www.ebay.com/itm/Drill-Americ...IAAOSwPCVX3d4V and a socket to drive it.
Right hand thread is ok.

the link refares to a die nut they are used usually to clean up a damaged thread of the same diameter and pitch and not to use to cut a new thread, a stock and die is used to cut a new threads. It's very difficult to get a good thread using a die nut from scratch.
perhaps the difficult job will be finding a nut with the correct diameter and thread pitch 19mm is not a standard size in metric coarse or fine sizes.

[AMK]

the link refares to a die nut they are used usually to clean up a damaged thread of the same diameter and pitch and not to use to cut a new thread, a stock and die is used to cut a new threads. It's very difficult to get a good thread using a die nut from scratch.
perhaps the difficult job will be finding a nut with the correct diameter and thread pitch 19mm is not a standard size in metric coarse or fine sizes.

Good catch. I used that link for an example assuming there was a HSS version.
After I checked further I couldn't find one. That shaft material would simply destroy that carbon steel.

But wait..https://www.icscuttingtools.com/catalog/page_238.pdf

[met]

thanks again everyone for your input....

i'm thinking................ is there any reason why using a split pin arrangement through the nut and shaft, wont work?
..............and for good measure, weld the nut in place as well....?

[AMK]

If you get a good thread on the shaft then Chuck's suggestion with the locking tab on the washer should be good enough. I wouldn't weld anything.

[chuck hahn]

Dont weld on it. That puts you right back where you are now when its time for a new set of sprockets and chain.......

[chuck hahn]

Cheap to replace. If you follow the service manual youll be done in a day. Use some Threebond 1184 for resealing the cases and have it right again.

http://www.ebay.com/itm/1980-Suzuki-GS750-Transmission-Assembly-24120-45400-24131-49002-09390-62012-/182313084870?hash=item2a72b4e7c6:g:igQAAOSwzaJX~-Za&vxp=mtr#viTabs_0