Agreed... may they die a peasant's death.

Well, it sucks that there's no good aluminum welders around you, because that would be your best bet for a proper fix. BUT! Check out this YouTube vid - you might consider this option:

 

That's awesome! I was actually thinking of something similar. His idea seems more secure however. Hmm guess its off to Lowes to see what I can see. Thanks Jeff

 

You're welcome!
Should be an easy job, and I agree that he should have left the OD of the bolt a hair or two larger, so that heat would be needed to get the pin over it... good luck!

 

Great minds think alike.. I definitely want it as snug as It can be. I dont want to have to repeat this again lol.

 

If you do choose this route, keep us posted on how it goes.

 

Most definitely will. I decided to wait til this weekend so I don't break stuff lol

 

Picked up a portable compressor strong enough to use my air tools for $60 at the pawn shop thanks to my wife. ( learned not to tell her my doubts either cause she'll make me prove she's right) So anyways I got to do something to my bike today. First off, removed the Damn clutch basket.



Next moved on to the oil pan cooler and oil pan


Oh lookie what I found... Yeah, the other part of the starter boss... By the marking inside, it's been there for awhile.


Definitely not a good thing. Anyways, that's out. Now these six bolts inside the oil pan


After that, seperated the case and wala



Overall, bearings look good, end play is within specs. So looks like just a swap the trans, fix the starter boss and back in she goes.. here you can kinda see the damage to second gear. Instead of being flat like normal, they are at more then a 45. I'll post better pics when I take it out tomorrow.

Feels great getting something done finally. Would have still been going but lost daylight. I have no shop so it's all under the carport with the sand floor ha! Sorry bout that crap pics, all I have is my phone.

 

Not allot of progress to report. Been busy moving and all. Got second gear replaced and put back in. Had to replace the shift fork too seeing as how one side was rubbed completely flat. Forgot to get a pic of that but I will later. All that'sleft now is tobutton itall up and hope it works(I didn't forget anything)

 

Gary, it looks like your pic links are all broken on that last post.

 

Thanks, fixed it I think. Apparently I moved what album they were in. I really dislike photobucket but its easier to use on my phone then imageshack.