I have a worn (fretted) output shaft. Sledge got it right, http://gstwins.com/gsboard/index.php?topic=43130.msg484400#msg484400 (http://gstwins.com/gsboard/index.php?topic=43130.msg484400#msg484400) though the old sprocket wore more than the shaft did, so it's not giving me the willies to ride it with the new sprocket - but considering the cost of new part + time to get the transmission apart and what-not .vs. grabbing a newer engine from a wrecked bike, I'm inclined to start looking for a newer engine to swap in this winter. If I want all the benefits of a newer engine, I'm trying to see what set of parts I want to get.
Any engine newer than 94 will have the thicker sprocket, which should be less prone to the type of wear. Never-the-less, grease your sprocket splines, folks.
2001+ has the 3-circuit carbs, if I get an engine with carbs?
2001+ (or is it 2004+?) also has the electronic tach, so I would need a tach to go with?
I'd need the CDI box to go with the new engine sensors, preferably. Might also need to drive the electronic tach.
Would I need a whole new wiring harness?
Hmm - perhaps I look for an entire pretzeled 2001+ or 2004+ and swap the bits in.
Thoughts?
The worn spline ... my 89 was that way since it had 15K and that was when I saw it. It had a major wobble in the sproket. That may have caused by sproket to wear a little, but it was a non issue totally. The fix is actually to drill and tap it for a bolt, then put a 530 sproket in it, and bolt it down with the right spacers/washers. I however never did it, and never had an issue. ~25K the chain came loose and escaped. I thought the sproket was the problem. Nope ... master clip came off ... got new chain and rode it 23K more miles, got goats - the buddha version, got many many other problems ... never a sproket problem.
You are burning the house to kill a fly. BTW I will buy your motor when you're done if you make me a deal on it.
The other thing is ... after you burn up your all brick luxury 19th century Victorian, you are building a drywall and vinyl tract condo in its place by putting in a new motor in it.
You get a fly, you open a window and wait. I'd just drill and tap it and ride ... or atleast put a 89-95 motor in it. Atleast you're putting in a better motor than you have.
Cool.
Buddha.
Perhaps I'll just leave it alone, then, or grease up a sprocket and clean the heck out of the shaft, then smear with "plastic titanium" (silly stuff from the makers of "plastic steel", which is still only about half the strength of plain old mild steel, but which is twice as strong as plastic steel) that I have left from a major bodge on my backhoe, and see if that (as spline tooth filler) stays put for any length of time.