Reviving this thread, because guess what?
Insurers said I could keep it, they didnt even want it. So I thought Id take off all the damaged fairings, and naked it. Seeing as the headlights are crap anyway Id fit a single round HID or something.
So its been sat up in the garage for a month, once the insurance examiner came round and had a look at it, and declared it a write off I got to work. New bars, fairing etc all taken off so I could at least steer it, the old fairing was so bent that with new bars on I couldnt do full lock either direction. Started it up first time with no problem whatsoever, took it for a test ride around the block, 5 minutes max. Satisfied it was working ok. Put it back in the garage... thismorning... theres a puddle of oil underneath it.
From exactly the same place.
Theres a hairline crack in
exactly the same place as the old sump
I cant for the life of me figure out why this is happening... I checked the new sump thoroughly, caked it in white spirit and scrubbed it til it was shining to make sure there was no cracks or other hidden surprises. Theres no moving parts inside the sump to be fouling it... I used a torque wrench to tighten the bolts to the correct torque in the manual... and a 5 minute ride has been enough to cause exactly the same crack to appear.
WHAT THE FOC?
What now? Do I try a 3rd sump? A friend has suggested taking the original sump to a garage and seeing if they can weld the crack, put it back on and see if it cracks again or if another fault develops. I think the sump is aluminium I didnt think that was weldable? Or perhaps some liquid metal weld stuff in the crack? But the heat expansion seems to make the crack worse over time, so I dont know if a repair would hold. Im quickly losing my rag with this bike. I love it and I want to keep it, plus the amount theve offered me is a mere pittance thats not enough to buy a replacement bike (£930, Im haggling in the hope for more... even the cheapest Fazers on eBay/Autotrader are around £12-1300)