A little mechanical excitement

[SportsterDoc]

Probably torqued too little, no blue loctite, and 90037-422-003 worked its way loose until it contacted the cover and started wobbling against it. If 90037-422-003 is too short for contact, then it may have just been launched into the cover. E=MC2

[Blockhead_imp]

I’m glad you’re ok Cormanus, and that this didn’t escalate into a mishap on the highway.

[Gone in 60]

What I sort of find odd is, isn't the bolt threaded in such a way that the rotation of the sprocket would work to tighten it? I remember that being the case on my Nighthawk. As others have said, good thing it didn't become a safety issue for you!

[GoldOxide_imp]

Cormanus: I reckon if you repair it (vs. replace it), folks are gonna wanna share in the resultant [Battle] Scar.



(... only quarters for meals, feel the way I feel ... )

[Cormanus]

Thanks for the kind words all. It could have been very ugly,I guess, but I'm not completely sure the sprocket could have come off the countershaft due to the limited space between the end of the shaft and the inside of the cover. However, I hope never to get a definitive answer to that question.

As to the cover, it has at least one crack heading out from the hole and it holds the slave cylinder for the clutch. I'm planning to keep using it as is until the replacement arrives.

I may stuff and mount the damaged article somewhere in the garage after that.

[jimgl3_imp]

Probably torqued too little, no blue loctite, and 90037-422-003 worked its way loose until it contacted the cover and started wobbling against it. If 90037-422-003 is too short for contact, then it may have just been launched into the cover. E=MC2

no blue loctite +1!

[Lord Popgun]

Just for info, the service manual does not call for thread locker on the drive sprocket bolt. Although, it does seem like a good ideal to add some.

[Gone in 60]

Cormanus, you could do what top fuel and funny car drivers do with their damaged parts. Autograph it and sell it to one of your adoring fans.

[Cormanus]

[Stichill_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

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...

Ha! I did something like this on my BMW. A plastic tab on the fairing snapped off. I took some copper nails, cut the heads off, and flattened them with a hammer. Then I embedded them in epoxy as reinforcement across the broken section. Worked great, probably stronger than new! And, less than the USD $575 cost of a new plastic panel.