Broken part? We may be able to recreate it — ask us about this part.

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Estimated cost: $25 – $60
Estimated print time: 2–4 hours
Final pricing is confirmed by quote.

We keep getting asked about this one — the chain guard is one of those KTM parts that fails long before the rest of the unit is done. With your sample on the bench this is a realistic reproduction job.

Why these break

Chain guard cracks at the mounting holes. The original was moulded thin to save cents at production volume. That was fine when the plastic was fresh — twenty years on, there's no margin left in it.

How we reproduce them

Bring in the broken part and we'll reverse engineer it — usually with a design tweak that addresses why it failed in the first place, not just a copy of the weak original.

We print these in PETG-CF. Carbon-fibre PETG is noticeably stiffer than the stock plastic, so the part holds its shape under clamping force instead of slowly creeping loose.

As with everything in our library: whether a part can be reproduced depends on size, load, heat, material, and having a decent sample to work from. Send photos first — the assessment costs you nothing, and we'll tell you honestly if a genuine spare is the better option.

Part details

Manufacturer	KTM
Vehicle / equipment type	Motorcycle
Common failure mode	Chain guard cracks at the mounting holes
Typical use case	Direct replacement for the original chain guard on the KTM.

Printing & reverse engineering

Can print directly	No
Can scan from broken sample	Yes
Can redesign / improve	Yes
Recommended material	PETG-CF
Alternative materials	ASA
Print technology	FDM
Difficulty	Medium
Estimated print time	2–4 hours
Estimated cost range	$25 – $60
Expected lifespan	4–6 years under clamping load
Outdoor suitable	Yes
Heat resistant	No
Load bearing	Depends
Requires post-processing	No