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Old 11-18-2012, 02:58 PM   #1
Ridemuch OP
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1150GSA Engine Guard Problem..

I was ready to change the oil on my bike when I noticed something wrong with the engine guard. Some how the bottom of the guard that attaches to the engine and plate snap clean.

Has this happen to anyone else on here?
I first thought it was the fact that I was missing a bolt. But now I'm thinking could it be that I put the cross brace on from the back and not the front? Can anyone on here confirm this was the problem?

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Old 11-18-2012, 03:07 PM   #2
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You learn pretty quick which bolts to undo and which ones not to touch during an oil change. Get the wrong ones and putting it back together is a PITA. Also, the bolt lengths are critical as they are all M6 but all of different lengths.

However, I doubt that putting the cross bar on back to front could cause the bar to snap. More likely, it was dropped on that side at some point. Just get it welded up and forget about it.
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Old 11-19-2012, 02:06 PM   #3
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It's never been drop.
If you look that the cross brace on your bike you will see that it's tapered on one side of the bar. I'm thinking that from the last time I changed the oil till now it must have put a steady pressure on it make it snap.

Just saying
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Old 11-19-2012, 08:16 PM   #4
Geoff Hayes
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Welcome to the club!

I have an 04 GSA with the factory engine guards and mine have broken 3 times. My bike has been dumped multiple times but always at low speed and the guards have never been bent or damaged. Everytime they broke I noticed a rattle at about 4500 rpm's. I've rewelded them each time only to have them break at another mounting point. I repeat. My welds have not broken but the bars have snapped in three separate locations. I finally bought another factory set and have had no problems in the last year knock on wood. I have heard this from a couple other 2004 GSA owners. Perhaps bad metallurgy? I get the impression that it is due to vibrations because each time was after long road trips where the bike was run at steady rpms for hours. By the way they are not stainless but are painted. I discovered this when welding.
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Old 11-20-2012, 11:50 AM   #5
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No issues with mine.I have 186,000 miles. A few drops on either side at zero mph.
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Old 11-20-2012, 06:31 PM   #6
JurgenB
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Mine broke in a different point yet quite similar, right where the left bar attaches to the engine in the rear attachment point. I replaced that part of the bar, OK since.
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Old 11-21-2012, 06:08 AM   #7
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My first impression of the failure is crash damage; deformed bar stressing the flat.
But, that flat is stressed by the smaller piece welded to it upstream from the break.
I suspect fatigue as a result if improper weld sequence.
Since with the part loose the break is not aligned.
The missing bolt had nothing to do with the failure. I'd have it welded up and go on riding.
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Old 11-23-2012, 04:32 PM   #8
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If they are not SS what welding rod do I use?
Anyone?
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