A couple of riders on the the Tiger 800 forum have reported corrosion on engine covers and other parts. Both of the riders live in GB and many others in GB report they do not have this problem. I have no corrosion on my XC.





This is the best explanation that I read in the thread:





This is the best explanation that I read in the thread:
Steel is easier to paint than aluminium, eg the filter housing. Aluminium as in the engine cases is a different proposition altogether, because any micro porosity starts corrosion which travels under the paint and lifts it since the products of corrosion are much more bulky than the ally they replace. The problem is particularly bad where there is a line between paint and unpainted ally as at the edge of castings or machined bolt holes. BMW bikes have exactly the same issues you have described on your bike.
I don't know where the 800 is made but if it is here in the UK then the issue is made worse by EU rules requiring water based paint to be used
Cast aluminium will always require a chemical treatment of some guise, firstly to remove the graphite that occurs on the surface and to create a reasonable key for the external coating to adhere to. the best any dealer or painter is going to be able to do is create that required key using an abrasive source (sandpaper or localised sandblast of some description) and degrease the area using a relatively aggressive solvent the results of which could be acceptable done right.