Help Repairing My Beloved FZS

[Middy2000]

So I took the bike in for it's MOT. Passed without advisory.  She's a 2001 with just 10k on the clock and in immaculate condition.  Filled her up with petrol on way home and as I turn out the petrol station the arse end kicks out and she goes down on the left hand side. 


To say I'm devastated would be an understatement.


Damage sustained.


Alternator casing smashed.
Mirror Scuffed
Front Fairing Smashed
Front Indicator ripped off
Rear fairing scuffed
Bar end scuffed
Clutch Lever scuffed
Rear indicator scuffed
Gear pedal bent
Rear pillion peg bent
Tank dented and scuffed


I rang the insurance who wrote it off in an instant.  Initially I was happy with this as I had spat my dummy out and that was me done for biking.


I've calmed a little and have now put the recovery on hold whilst I assess the costs to repair.  It's looking promising but I'm stuck on a few bit and could do with some help.


1.  Are the parts from Wemoto genuine Yamaha parts.  They have the clutch lever, indicators and mirror.
2.  Has anybody fitted one of the front fairings from Ebay.  Comes from Poland.  Looks a good copy.
3.  Where can you but the plastic rivets that hold the front infil panels from?
4.  Anybody got a perfect rear left pillion peg?
5.  Likewise for a alternator cover although I can get a used one from Ebay and have it stripped and powder coated. 
6.  Can you get the metal screws the hold the front fairing to the frame near the petrol tank?
7.  Is there a company that can remove dents from petrol tanks?  It's similar to a car park trolley dink on a car door.  Think the handlebars caused it.

I'm basically throwing myself at the mercy of you all to help me through and get her back to normal. 


Advice getting the front nose cone off would be useful too.  I think I'm nearly there but is there a guide on here somewhere?

[fazersharp]

Personally I would not replace things that are scuffed and the bent things - bend em back. Which only leaves the alternator cover to replace and Front Fairing and Indicator. I would probably also live with the dent in the tank. 

[Middy2000]

I can't pal, I feel I owe her it to put everything back as it was.  She was absolutely mint. 


I'm even being anal about the alternator cover as I can buy a brand new one but it's not branded Yamaha.  Hence I'm prepared to refurb one.


My only issue is I can't presently remove the remainder of the cover from the stator.  Seems to be held on with 3 bolts.  One of which the head is knackered.  Have to use some creativity in removing that.
I'm now stressing about finding a replacement allen bolt for that. 


I think all things considered it'll cost around £400 to put right.  An expensive incident but small fry compared to others misfortune and I came out completely unscathed personally.

[fazersharp]

My only issue is I can't presently remove the remainder of the cover from the stator.  Seems to be held on with 3 bolts.  One of which the head is knackered.  Have to use some creativity in removing that.
I'm now stressing about finding a replacement allen bolt for that. 

Don't worry about that because this forum is full of experts at removing 20 year old rounded nuts screws and bolts and someone will be a long shortly to advise there.

[Middy2000]

I'm confident it'll come off. It's not seized so can probably sort it using a set of mole grips or something like. 


This is the first port of call.  I've a mechanic mate coming round Saturday to diagnose things further.  At the minute the noise from the bike is horrendous but I think it is because the alternator cover is missing it is allowing all the engine noise to escape.  The bike seems to start and idle as it should.

[Zark]

ebay is terrific for small numbers of various fasteners.
search 'allen bolts,' and measure the length of one you've taken out. Similarly for the fairing fasteners - most stuff will be M4 or M6 thread.

While it's gutting - just think of it as an opportunity to refresh some stuff!





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[agricola]

I can't pal, I feel I owe her it to put everything back as it was.  She was absolutely mint. 


I'm even being anal about the alternator cover as I can buy a brand new one but it's not branded Yamaha.  Hence I'm prepared to refurb one.


My only issue is I can't presently remove the remainder of the cover from the stator.  Seems to be held on with 3 bolts.  One of which the head is knackered.  Have to use some creativity in removing that.
I'm now stressing about finding a replacement allen bolt for that. 


I think all things considered it'll cost around £400 to put right.  An expensive incident but small fry compared to others misfortune and I came out completely unscathed personally.

Allen screws can sometimes be removed by tapping a torx bit into the socket, and using that to screw the screw out. You want the size thats cuts into the sides of the socket as you tap it in

[Middy2000]

Thanks for that.  Like I say I'm confident it'll come out.  I'd not really made a decent attempt at it before posting this as I'm still at the trauma stage everytime I go in the garage.


The main focus is whether the nose fairings from Ebay are any good.  That's the bulk of the cost to repair what with the spraying. 

[His Dudeness]

I'd go for good used parts off ebay but you can get genuine parts here https://www.fowlersparts.co.uk/

[Middy2000]

Bolt removed from stator and the broken casing is now in the bin.


I've left the stator connected and just hanging loose.  The bike no longer starts.  Is there some form of ignition pick up within the stator that might prevent this?

[His Dudeness]

The pickup coil is beside the stator. It has a white dot on it in this picture.

[Middy2000]

Thanks for that.  That's presently unscrewed from the casing but still connected to the wiring harness.  Would this prevent it starting?  I guess it's not earthed as I've got it.

[His Dudeness]

Thanks for that.  That's presently unscrewed from the casing but still connected to the wiring harness.  Would this prevent it starting?  I guess it's not earthed as I've got it.

Yea without the pickup coil there would be no signal sent to the ignitor to tell it when to fire the spark plugs so no spark. It has earth. It has two wires one is earth the other one is the signal wire back to the ignitor. It needs to be bolted into the engine cover to create the signal at the right time as the rotor spins past it

[Middy2000]

Perfect answer.  That explains everything. 


Many thanks. 

[Middy2000]

So I got a used cover off Ebay.


It was a bit scuffed and battle scarred.  Had it refurbed.


Fitted it and bingo, everything is normal.  Bike fired up straight away and all the issues around excess noise has gone which confirms that I've got away with purely cosmetic damage.


Bought a new front fairing and had it sprayed along with the damage to the rear fairing patched up. 
New indicators, wing mirrors, bar ends, clutch lever and decals to be fitted and fingers crossed she's as good as new.


Only slight issue is the front fairing has been sprayed completely silver on the inside and I'm not sure I like it.

[Gnasher]

Good result 

[fazersharp]

Only slight issue is the front fairing has been sprayed completely silver on the inside and I'm not sure I like it.

Not sure what you mean there - owning a black bike my fairing is black on the inside, are other colour  :faz fairing also black on the inside then ?

[vinnyb]

[quote author=Middy2000 link=topic=25878.msg309396#msg309396 date=1581881827]

Only slight issue is the front fairing has been sprayed completely silver on the inside and I'm not sure I like it.

Not sure what you mean there - owning a black bike my fairing is black on the inside, are other colour  :faz fairing also black on the inside then ?

[/quote]
  My blue foxeye is sprayed blue inside the fairing not left black

[bandit]

[quote author=Middy2000 link=topic=25878.msg309396#msg309396 date=1581881827]

Only slight issue is the front fairing has been sprayed completely silver on the inside and I'm not sure I like it.

Not sure what you mean there - owning a black bike my fairing is black on the inside, are other colour  :faz fairing also black on the inside then ?
[/quote]




98 Fazer in red is black inside fairing also.

[Middy2000]

Original was black plastic inside. The new one was black as standard but I didn't actually tell the sprayer to leave it like that and to be fair it was easier to do the whole lot rather than mask it off. Probably won't see much once it's fitted.