34L output shaft spline wear
 

Hi Everyone from wayyyyy down south. Glorious Wanaka, South Island of NZ. Long time listener, first time caller!!

I've got a bit of a challenge, my 34L has got a worn spline on the output shaft from the gearbox where the front sprocket sits. Mines the old style that has the retaining plate and 2 bolts to hold the sprocket on. The shaft has about 1mm wear on the outer 6 mm. The ideal would be to replace the shaft, but my budget doesn't stretch that far at the moment. I would like to and have a look a 5th gear at the same time, but I want to get the old girl ready for some adventure riding this summer and maybe make it a project next winter.

Here's what I'm thinking.......I can get a replacement sprocket that has an extra 6mm shoulder, which makes it 12mm wide and would take up all of the spline and share the load across the rest of the spline. As a token gesture, I was thinking of putting some of that 2 part epoxy metal repair stuff on the spline and a new lock plate.

Has anyone had any similar problems or offer any advice?

Thanks