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Discussion Starter #1
Pulled my front sprocket off and this metal tab broke while cleaning all the gunk off. With hardly any pressure it just snapped right off...

The plastic cover goes over top so I'm guessing this is no big deal...or should I try to get it welded?





 

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...I would clean it WELL with acetone or similar and use JB weld

It is a non stressed part and I suspect it would last well
 

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That looks like part of the engine casting, it could be a manufacturing defect, I would contact Kawi to see what they have to say. There is no other logical reason for it to fail given the thickness of the metal and it is unstressed.
 

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Discussion Starter #4
That looks like part of the engine casting, it could be a manufacturing defect, I would contact Kawi to see what they have to say. There is no other logical reason for it to fail given the thickness of the metal and it is unstressed.
Is there any point in contacting kawi if the bike is out of warranty?
 

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That could easily have been caused by a rock getting jammed between the chain and the casing. I have found rocks "down there" before, and the aluminum engine casting will break before steel will. It looks like that casing is there to prevent chain lube from flinging forward, something which the plastic cover also does. As rcfield said, jb weld it if it bothers you.
 

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No chain wear marks on it? Some have reported some contact when using a 16T sprocket, and expressed their desire to try to bend it out. It is cast aluminum, which breaks before it bends.
 

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Discussion Starter #8
Are you sure you didn't cause it with whatever tools you used to get off the sprocket?
I don't think so.. I did have a rag stuffed on the inside of the chain in front of the sprocket (as well as on the rear) to keep it from moving while trying to break the nut free. But I don't remember the rag making it's way around the sprocket to contact that piece. I also used a small flat head screwdriver to remove all the gunk, then a rag to clean it. As I was cleaning it with the rag it just came off in my hands. I wasn't using much pressure at all...
 

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Discussion Starter #9
No chain wear marks on it? Some have reported some contact when using a 16T sprocket, and expressed their desire to try to bend it out. It is made of cast aluminum, which breaks before it bends.
I always ran stock sprocket on the front. If the chain was hitting it then wouldn't it be free of gunk? Although it did come across my mind that if my chain was loose it could have slapped it?? But I don't really see any evidence of that.
 

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Yeah, I wouldn't worry about it. Maybe just paint the bare aluminum black. It probably just passed a stone or something... It won't break again.
 

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The gunk was acting like glue. Just clean the broken edges and epoxy/JB weld back into place. No one will ever know but you.
 

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It wasn't completely broken, nor was it held on by any gunk... It was partially cracked and nearly broken off. The crack was still tight and remained clean. It broke off while he was cleaning it.
 

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+1 for JB Weld... It wouldn't hurt to stick it back on there... or it probably wouldn't hurt to leave it off. If it were mine, I'd stick it back on just for the heck of it.
 

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Is there any point in contacting kawi if the bike is out of warranty?
From my experience with cars both VW and Honda have had extended warranties that covered repairs to parts out of warranty they have later found to have a defect. The only reason I can see something like that breaking the way it did is a manufacturing defect in the casting of the metal. Although they may not cover it at least it will go on record and if they get similar complaints down the road they will see a trend.
 
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