Okay, so back to Jorge’s garage again, we pop off the cover and examine the gasket.  It’s on the cover perfectly; no bends, no rips, no reason why it should be leaking.  We wipe it down, and take a closer look at the cover, and finally we find out the problem.   There are two hairline cracks in the cover each about an inch long. 

Apparently, when the Alex and Justin pulled the covers from the Daytona 675 to put on the Street Triple, they overtightened those areas, and cracked the casing (come on guys…arghhh!!!).  And, as we all know, the cracks only widen as the metal expands under the extreme heat. 

So we had two options: One, get a new cover, and wait who knows how long for the part, or two, try JB Weld, do it right then and there, and hopefully it will hold.   It was a no brainer.  Let’s do the JB Weld, and hope it holds.  The bike had spent way too much time in the garage, and I really needed to get back on it.

It’s a pretty simple process when you do it.  You’ll be fixing the crack from the inside, not the outside.  Again, first be sure to clean everything well.  You don’t want the crack areas oily at all.  Next, you should take some fine sand paper, and rough up the around the crack.  This allows the compound to get into the metal, and hold better.  Here’s a pic:

Once that’s done you simple mix up the JB Weld Compounds, and apply to the crack area.  Finally, you’ll want to let it dry for at least 6 hours.  We just let it sit overnight to be safe.

Then it’s just a matter of putting it all back together, and putting the oil back in.  It took some time, but we were ultimately able to figure it out.   So far there’s no more leaks, and it looks fine… but most of all, it’s finally safe to ride hard.  Twisties here I come!

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