I've got no intention to do this yet but was just wondering.
If a bike is running total loss it no longer needs such a big cover due to the lack of rotor, could a shallower/lighter cover be used?
what would be a suitable material? ally? fiberglass?

You could, but the weight saving benefits wouldn't be worth the hassle and money spent on making/getting a new cover.
my personal opinion.

Your time would be better focused on other parts coming into your first season, if you do decide to do this.

The end of the crank protrudes too far so you cant just make a flat cover on the cheap as it would need milling out etc, I know someone who chopped the end of the crank off with a hacksaw and used a flat piece of ali to make it work though...

ChowderV4 wrote:You could, but the weight saving benefits wouldn't be worth the hassle and money spent on making/getting a new cover.
my personal opinion.

Your time would be better focused on other parts coming into your first season, if you do decide to do this.

I wasn't intending on doing it soon. Just wondered if anyone had before.

Thanks for the replies, sounds like it is something possible to do if you really want to go to extremes

oh yeah definately possible.

A friend i race with with NG had a zxr that has had the whole generator casing removed and ground smooth to the crankcases. no starter motor or gear and just a plug in the end of the crankshaft.

So anythings possible haha

The bike is mega tuned.