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Well, after losing the front sprocket and resulting damage, my bike has languished at the side of my house until now (had to bust a hole in a brick wall etc to get the bike into my new workshop). Starting to sort out the damage caused and thought a few pics might keep you entertained for a couple of mins. Phone photos so a bit crap I'm afraid.

1st pics show where the sprocket ended up. Tried to eat its way into the bottom cross member on the frame. It was stopped by the swingarm. Fortunately there is only 'minor' damage (cosmetic) to both which you can't see once the sprocket cover is on. I had to drop the swingarm out to get the sprocket/chain out however without causing more damage.






2nd pics show the damage that is causing concern. Around the gear selector shaft should be an oil seal held in place by part of the engine casing. This has been smashed off in 2/3rds so nothing to hole the oil seal in now. I'm hoping I might be able to get a jubilee clip on as there is just enough material there I hope. If not.............new engine? Anyone got any ideas?

Sorry if I missed an earlier thread on this.... but how did the sprocket come off? Did the bolt come loose or did the head shear off?

Bolt came loose. First I knew was a big bang and no drive at 70mph. I thought the gearbox had gone! Still, could have been worse and I have a few ideas up my sleeve to try. Go check yr bolt is tight please! (its a problem with the new Tuonos too it would seem).

If you were really good, you could build up the area using chemical metal. you'd have to grease the shaft, seals, etc etc in order to prevent it from setting to the shaft, and possibly utilise a greased jubilee clip to do the outer surface...to get a semi decent housing finish..if that makes sense..

Ive got 'stuff' at work for doing battlefield damage repairs, I could possibly get you a couple of sachets of it.. it's like chemical metal, but the proper stuff.. you can build engine components out of it!!

Definately better than a whole new engine..

That would be brilliant m8, thanks. I 'think' I can get a jubilee clip on to it and have just ordered a few seals to play with too so would appreciate the sachet and i'll try building it up round the seal. Its not a high load area so I'd hope it'll fix ok.

May have to wait til after the 7th to get my mitts on it (on leave at the mo)
if you can wait that long then shouldnt be a problem. if you cant, i'd suggest using chem. metal, but drilling small holes into the existing area and sticking metal dowels into it to help hold the chem. metal in place... reckon that'll make sense when i post it...(he says..)
Shouldnt need it with the stuff ive got at work tho' as it's proper stuff, not cheap tat from hellfords..

Aye, that'll be champion thanks, no panic as i've plenty to be getting on with in the meantime. Give me a shout and I'll pm you my address. Thanks! Let me know if you want any cash/postage too.

Right, got you a sachet of the stuff and the activator. Just need your address for sending them to. Pm please!

Basic instructions for use:

Usual safety applies as for say car body filler.. use same sort of mixing surface and spatula.

Mix in equal amounts of each packet,

Apply to clean dirt free surface

Goes off hard in 3 minutes, so be quick with it!

Oh and use the gloves I'll send with it.

Remember too to shield the shaft with something or it'll stick like sh*t to a blanket!!

It may heat up slightly in use. this is normal

Cheers m8, have pm-ed you wi my address.

Will post up on progress. Hopefully the posty has all my genuine parts for me this week too.

Will ask the missus to post it on tomorrow for you.

Big Un, did it work in the end?

yeh wee want to know !

Dunno about Bigun's repair .... but that battlefield repair kit seems to have done a good job on my lad's scooter.

Thanks Tim

Yes, in a fashion. The metal epoxy is brill stuff but I've still got a little weep from somewhere. Thought all was brilliant, left in my workshop for a few days, no leaks or anything. Put it all back together and took it for a run. All brill there (stopped a couple of times and no pool under bike). Got home and it starts weeping from the same area. Haven't had time to check it yet as I'm in the process of putting a new kitchen in but fingers crossed its no too much to worry about. Still got some stuff to bung it up with.

bigun wrote:Bolt came loose. First I knew was a big bang and no drive at 70mph. I thought the gearbox had gone! Still, could have been worse and I have a few ideas up my sleeve to try. Go check yr bolt is tight please! (its a problem with the new Tuonos too it would seem).

Yup, your right M8, mine was finger tight with no sign of any locktight having ever been applied.

The job has now been done properly

F9