A little mechanical excitement

[Lord Popgun]

Cormanus,

The good thing is you are OK. As we always say, the bike can be repaired. I'm glad though that the damage isn't too bad.

[GoldOxide_imp]

Having piled on that much luv (~120,000 kms), I suppose the odd episode can happen. The bike has "war wound" character, maybe temporarily enhanced with some duct tape (or better) until you bother with formal repair? A big heat resistant band-aid?

Nevertheless, glad it read it wasn't something serious enough to kick you off the bike at speed.

[Ben70_imp]

If we lived in the post apocalyptic world of Mad Max, with no reasonable alternative, I would suggest thorough cleaning, duct tape the hole outer surface, pour liquid steel or some such into the cavity, Let dry, remove tape, cross fingers, and go another gazillion km.

Ben

[suhawk305]

I guess if there is any good with this is there wasn’t enough space between the end of the countershaft spline and the inside of the cover for the sprocket to come off the shaft and get wedged between the end of the shaft and cover. Could have caused a dangerous situation while riding.

[LongRanger_imp]

Wow. Just wow. Certainly glad this didn't cause an accident while you were riding.

[Rocky_imp]

If we lived in the post apocalyptic world of Mad Max, with no reasonable alternative, I would suggest thorough cleaning, duct tape the hole outer surface, pour liquid steel or some such into the cavity, Let dry, remove tape, cross fingers, and go another gazillion km.

Ben

I thought of something like that too, but would be concerned that vibration, heat expansion and contraction might eventually break it free.
Since the cover is out of sight I like the welding option better as suggested by Razor.
All that said, I suppose if it was me I would buy a new cover

[Django]

If we lived in the post apocalyptic world of Mad Max, with no reasonable alternative, I would suggest thorough cleaning, duct tape the hole outer surface, pour liquid steel or some such into the cavity, Let dry, remove tape, cross fingers, and go another gazillion km.

Ben

That's the way to go! I would add 1-2 bent stainless steel paper-clips to give more stability, like iron in concrete.

But then, that's probably German uber engineering again...

[Gone in 60]

"If we lived in the post apocalyptic world of Mad Max, with no reasonable alternative, I would suggest thorough cleaning, duct tape the hole outer surface, pour liquid steel or some such into the cavity, Let dry, remove tape, cross fingers, and go another gazillion km."

As I was reading this, I was thinking of something I did long ago to fix a hole in a transmission case on a truck. Find the largest coin that will fit in that hole if you were to round the hole out a bit so the coin has something to "grab". Tape one side of the hole, put the coin in for some structure, JB Weld, fingers crossed.

I had the luxury of being able to look under the truck repeatedly for many miles until I was satisfied that the repair would hold. If you ran without the plastic cover over the sprocket for a while, you might be able to do the same.

[SportsterDoc]

https://www.ebay.com/i/352565772717?chn=...gKGS_D_BwE

[misterprofessionality]

to elaborate on some things that have already been said, could the puncture in the front sprocket cover have been caused by the bolt being torqued too much, or was it a case of it being torqued too little? either way, i can't fathom forces involved in launching a nut through solid metal with enough force to create what looks like a bullet hole.