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pkbinder 10-17-2012 04:39 PM

I sprung a leak!
I have an 09 800GS. The original owner, a stand-up guy who is a regular on this forum, fixed a leak in the lower case with JB Weld that has lasted almost two years. It started to leak again 2 months ago, so I wire wheeled the paint and some, but not all, of the JB off and replastered it with more JB. I was ecstatic that I stopped the leak. But, alas, the leak is back. Smarter folks than I tell me I should find a welder who can weld aluminum, as apparently that is somewhat of a specialized art. The original leak came about when the bike crashed on its left side. There are two connection points for the crash bars on the lower case. The impact caused a small tear in the case right where the crash bars connect, and thus the leak. Any of youse guys have any thoughts on the matter?

GH41 10-17-2012 05:22 PM

I hope the price you paid was low enough to allow to properly repair of the case. JB weld is something you use to get you home. It is a patch not a repair!!!! GH

pkbinder 10-17-2012 06:07 PM

Yes, the price cerainly did reflect the conditon of the bike. Full discosure and all that. But thanks for the advice anyway. pk

Indy Unlimited 10-17-2012 06:48 PM

I would buy a new case if the crash guards are still using that for a mount.
If it is too expensive to replace then look into different crash bars that do not mount on that location and just redo the JB weld.
The reason the JB weld is leaking is due to the stress induced by the crash bars and not the JB weld just wearing out.
I use JB weld to repair cracked intake ports on heads and it hold up for life if done right.

grndzr0 10-17-2012 09:53 PM

IF you decide to go the welded route, make sure it is a very reputable shop, like a machine shop of some type. If they know what they are doing, I would trust them. (Like if you show it to them and the look comfortable doing it....) It would be wayyyyy cheaper than a new case.


sorebutt 10-18-2012 09:23 PM

I've had broken cases welded on other bikes and never had a problem. The weld is usually stronger than the rest of the case.

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