Just put a new front sprocket on and noticed it was as loose as the old one I took off.....i can get it locked with the licking washer bolted on but still has maybe 2mm of movement back and fore...
I'm guessing the splines are worn...
So questions are!!!
Can I just leave it as it is?
Theres a space behind the sprocket so could I modify the old sprocket and tig weld it or drill and thread it and use longer locking bolts to lock it in..??
Or and I don't really want to split the motor, is it a case of a new output shaft?
I did a search earlier and am sure the shaft from an xv250 was mentioned as the same part but way cheaper...

My personal opinion is don't worry about it, it's not going to fall off.

Mezo.

Thanks for that
This is the wear on the splines..

I know honda sfica twin have a modified sprocket
https://www.kkbike.it/en/sprockets/141- ... 50123.html
I wouldn't ride with it loose - look to do your own modification that uses some of the good spline or replace shaft

• You can machine down another sprocket to washer diameter and then tack weld it ro the sprocket, which doubles the surface against the splines and nearly stops the wear.
• There is a guy in Germany selling an extra peace of kit which is exactly for pulling the sprocket against the nut, all new parts and exactly fitting, but shipping may be costly and I do not know if he sends outside Germany ...
  https://m.ebay-kleinanzeigen.de/s-anzei ... 6-306-2862
  
  Or click https://ebay-kleinanzeigen.de and search "xt-tt600-350-srx6-ritzelsicherung-doppelt"
  The guy has ads there regularly, and the stuff works well, plug and play.
• Some other options, but less elegant:
  https://www.xt-foren.de/xt-phpbb/viewto ... 4&p=168712

Andy

What ever you do, eventually that shaft will need changing

Can't argue that..
Is there a shaft from a later motor that will
Fit with just the Bolt securing method..

OR is there a Yamaha shaft from a different
Bike that could be utilised when I do eventually change the shaft...??