1984 49r Xt600

[Trainman]

Hello All,
New to the forum but have been learning a lot just reading about other ppls issues and solutions for their XT's.
I just purchased my fist XT600 on 7/12/07 for $400. Bought it off a colledge kid who thought it was just a huge dirt bike. The bike runs great and is in over all good condition. The bike was painted flat black with Krylon BB-Q paint and was hard on the eyes. Took it home and my heart missed a beat when I started to scrape the BB-Q paint off and the orriginal paint and stickers were in excellent shape. Bike looks great now.
Now the real problem. The person who owned the bike b4 me, put an after market sproket on the front. He secured the sprocket with a clip (and no spacers) instead of a bolt on retainer. The sprocket and chain move over and started an abusive relationship with the case. A very tiny hole was eaten into the case and now leaks oil. Ive replaced the sprocket and reatiner but still have a small hole in the case. Spot welding and re heat treating the case are very expensive. Are there any other solutions, like brazing, soldering, or even JB weld that may work. The whole is so small it cannot be seen but oil comes out at about a teaspoon per minute.
Also, droped a tooth on the front sprocket down to a 14, is there a problem with going to a smaller sprocket on this bike.

Any help will be apreciated.

Thanks


I also ride a 1983 TT250 trail bike, 1993 YZ490 hairscramble bike (aka, widowmaker, rated #4 worste bike in the world).

[yhprum]

I'd lay the bike over so no oil can leak out, wash it throughly with something like brake cleaner and try some JB weld. If it doesnt work, you are not out much. Pictures would help too.
Good luck, steve

[Trainman]

Thanks, will give that a try. Let you know how it goes.

[Trainman]

It worked!

Cleaned it with break cleaner and did a light sanding, re-cleaned and put on the jb weld. let it sit for 24 hours and then went for a ride, about 120 miles, and no leak.

Thanks for the help.

[Walkabout]

Trainman,
That's a great example of a metal repair! It's a bit late to help you now, but I have been pulling together a few examples of what metal repair materials can be used to repair bikes and in what circumstances they work OK (or don't work, but no one seems to be admitting to that case!).

If you are interested it is here:-

http://www.horizonsunlimited.com/hub...l-repair-28199