Morning everyone

latest issue for me.  When I got this bike it came with the flywheel cover not fitted.  The cover supplied had some damage so I obtained a better one. When I came to fit it it wouldn’t.  It was touching the sprocket cover and wouldn’t let me align the holes in the cover with the crankcase. I removed the sprocket cover and discovered why. Looks like possible chain damage. An “interesting” repair done which isn’t quite in the right place.  This is causing my issue. 
I can modify the repair to be better I imagine.  I just wondered if anyone has a better solution.  I hope the pictures have posted.

i don’t want to change the crankcase as it’s the side with the number on and it’s matching to the frame.  

any ideas? Or should I just make the repair I have work.  It just doesn’t look pretty. 

thanks, ian

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That's a clever "get me by" repair. lot of force on it when operating the clutch but i guess ity must've worked ok. Carry on as best you can, but if you modify it be sure the clutch rod isn't compromised. I guess it must've worked as is so in theory it's fractionaly off a perfect clutch rod line now so whatever you do could make it better. I wonder how deep the original hole goes if you were to drill-tap it a bit deeper then space it out square in line with the top hole.. I'm certain one of mine is drilled right through-by mistake or desperation to get a threaded hole. Just sealant on the screw or 6mm bolt i used.

Thanks for that thiught.  The original hole is broken off almost flush. I was windering if i found a damaged crankcase with the area i need still intact coukd I cut iut and repair mine. But as you say a lot of stress there and not sure a metal paste would work. 

i dont want to have to strip the whole engine down to weld repair a piece in.  Though i guess i could find a case and put to one side in case i do a full engine build one day.  Would any RT or maybe an early DT case be the same for that fixing screw?  I realise they would be plenty different in other areas but i just need that 2 inches!

fir now i will try to make it fit better so i can line both covers up and fit them. Right now to fit the flywheel cover i could only get the top screews/bolts in. 

thanks again.