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Just my $.02 but it would seem prudent to consider an overhaul of the bottom end and all bearings and seals as a minimum. If this is an example of the PO's maintenance you might be better off to get ahead of the game here. Just a thought.

Bearing supporting that shaft at a BARE minimum

KDXGarage wrote: ↑03:51 pm Jul 19 2019 chain tension may have gone awry

That or a sloppy fitting sprocket from the get go or one left on way to long and then becoming sloppy. The counter shaft sprocket will wear just like a clutch basket from being on/off with the throttle only a lot slower.

I would use a die grinder but don’t cut too deep, you can shave it down then give it a hard tap to crack the weld loose but what I’m wondering is maybe it was welded because the spline teeth sheered, this happened to my bike so I welded it a certain way to take it off when I’m ready to replace it.

its normal for you to turn the output shaft and have a little play before the input shaft turns. Not changing sprockets and incorrect chain tensioning over a long period can cause this kind of wear. Someone did not believe in pre/post ride maintenance before you got it lol

Well here is what’s left when I got it off

What a mess but now

Looking at getting one of the older air cooled kdx now this is finished hoping for £2000 as they are very rare over here

Parney wrote: ↑01:58 pm Aug 02 2019 Well here is what’s left when I got it off

That’s crazy. Good luck in finding an air cooled. I love mine.