Posted by WD on April 25, 2003 at 09:26:24:
In Reply to: Broken aluminum cover posted by Ram on April 25, 2003 at 06:38:08:
Since it is cast aluminum, your best bet is to JB Weld or similar thr back side of it. I think cast can be repaired, but I'm not a welder. Call a local machine shop and see if their TIG unit can handle it. I've seen cracked cases for older HD Sportsters welded up, and they are cast, so if you have a local un-authorized HD shop, you might ask their fab guy as well. They'll probably give you some grief about riding a Japanese bike, but a good fab guy should answer your question anyway.
The other option, which looks kind of trick, is to paint your front pulley and leave off the front cover. Grit and debris will get in there more easily, so you would have to keep a close eye open for accelerated belt/pulley wear. The cover is mainly cosmetic, but does help keep out road crud.
Let us know how it turns out.
-WD