Is my Q-matic toast or easily fixed?

Note: I just emailed my dealer about this, but figured maybe some folks here had some pointers.

I've only been riding the bike about 2 weeks now, and it was mostly trips around the neighborhood. I did make two 6-mile round trips to work last week (since my plan all along was to commute on it during nice days) and didn't notice anything out of the ordinary. No loss of power. No weird smells that I could tell. No grinding noises or anything like that.

I made it back home from work last night with no problems. I figured I'd take the bike into town afterward since it's the weekend. Halfway into town, I heard what sounded like a loud howl that resonated through the bike. I immediately hit the kill switch. I did a quick inspection of the outside of the bike and didn't see anything wrong. Nothing externally was loose. I turned the bike back on and gave it a bit of throttle to check if the noise would come back, and by then it had stopped sending power to the rear wheel.

Since it was night time, I pedaled the bike back home and waited until daylight to try and find out what the matter was. I wound up taking my pedal bike into town, but by then the bars had closed. Weak.



Hmm....looks like something tried to escape from my transmission. The bike has never fallen over or been laid down on its side.



I removed the transmission case to find it was full of plastic and metal shavings. Hey, what's that little metal piece?



Turns out the key that sits in between the pulley and the drive shaft worked its way loose, grinding away the transmission cover before falling out completely, allowing the pulley and drive shaft to go out of sync.



It then allowed the pulley to slip and make contact with the transmission case, grinding away parts of both. I loosened the allen screw on the pulley to pull it forward to show the damage.

Before totally voiding my warranty, I figured I'd wait to hear back from my dealer before attempting to get the pulley and drive shaft lined back up, reinserting the key and tightening the allen screw back down to see if that holds. Or is that a horrible idea?

Thanks for the fast responses, guys! I got the notches in the pulley and shaft to line back up by yanking the pull start a few times with the choke off so it wouldn't fire. The key slid back in, but seems a bit loose in there. I think I might need a new pulley, though, as it looks like a chunk of it was ground off up to the set screw.



Also, what size bolt do I use on the end of the drive shaft? Were they left off because of clearance issues?

Thanks again. The bolt I needed turned out to be 1/4" x 28. I applied blue loctite to it and the hex screw after lining things up as best I could. I think the spring-loaded tensioner is wide enough to accommodate slight variations. I'll go for a ride after it cures for a bit. I may keep the cover as it is, but I kind of want to make the entire side clear lexan now.

EDIT: Just went for a ride around the neighborhood again. Everything stayed put. Not bad for about $5.