Fazer 600 '04 repairs!

Mister James · I want to believe! Joined: 10 Aug 2004 Karma :

Ok guys, I need a couple of bits of advice, as I've decided to repair the crash damage to my Fazer myself. (barring any major problems)

https://www.bikechatforums.com/viewtopic.php?t=37163 if you want to find out how I did it.

The list of damaged components is as follows:

Main fairing (£35 from a dealer after a previous problem)

Right mirror

Rear brake pedal

Tank (only dented - can be tolerated for now)

right footrest - specifically, the footrest is intact, but the bracket it is attached to has been sheered off.

Everything else seems fine, I rode the bike home 15 miles after the off, and it runs fine, steering is ok, etc etc.

Does anyone know of any websites that deal with yamaha (and thus Fazer) spares, so that I can order this stuff and gradually put the thing back together over the winter, or am I going to have to go through the dealer again?

Also, does anyone have any top tips for removing scratches and scuffs from the bike? It's got silver bodywork, the scuffs are fairly minor but they look shitty on what is essentially a brand new bike. Can body shops sort this kind of minor thing out effectively, how much would it cost, etc?

I'll attach pics of the damage when I get my digital camera back, as I appreciate much of what I have said probably makes little sense without people being able to see what I am talking about!

Thanks in advance for any advice....

Robby · Dirty Old Man Joined: 16 May 2002 Karma :

Parts will pop up on ebay from time to time, so keep an eye out.

T cut might get the scratches out, otherwise a bodyshop will be able to polish them out. Not sure what they use, but I can tell you they do a damn good job of it.

Mister James · I want to believe! Joined: 10 Aug 2004 Karma :

Well, I've managed to get the fairing panels off, and the rear brake lever, but I cannot undo the assembly that the footrest and brake pedal attach to - two of the allen bolts seem to be too tight to undo with hand tools, and the other two are of a size far larger than any tool that came in the owners tool kit.

Does this mean that the assembly/bracket in question is supposed to be serviced by a professional only, or is it just a case of getting the right tools to take it off?

Git · Brolly Dolly Joined: 17 Dec 2003 Karma :

The bolts for the footrest bracket are more than likely put together with some super duper thread lock, with the correct tools they should come off, just make sure you get an allen key or torx bit or whatever that fits really snug, combine that with a decent bar and they should crack off. An impact driver may make things a shade easier to break the thread lock.

mr jamez · World Chat Champion Joined: 04 Aug 2003 Karma :

Just buy a set of hex bit sockets, then just use those with a ratchet, much much better than hex keys, I have used mine loads on the bike.

Mister James · I want to believe! Joined: 10 Aug 2004 Karma :

Cheers guys, I'll pop into halfords tomorrow and see if they have what I need. It's a matter of both pride and bank-balance that I sort this thing out myself!

Guest · Brolly Dolly Joined: 22 Apr 2004 Karma :

You're looking for something like this .............

Mister James · I want to believe! Joined: 10 Aug 2004 Karma :

Been too busy to pop to Halfords for the ratchet and bits, but plan to do that one morning this week before work. The cost of the tools is probably offset by the savings in petrol riding the 100cc death 'ped into work!

Ordered the bits today, not too bad, £170 or there-abouts. That just leaves the chips and scuffs on the bodywork, and the dented tank. Will have to put up with those for now. Crash bungs are next on the list, after that I can start making it look pretty again.

Mister James · I want to believe! Joined: 10 Aug 2004 Karma :

Perfect - was going to go to halfords, but dropped into the local Robert Dyers and picked up a 61 piece for £10, as opposed to £30 for a 31 piece in Halfords! Nipped out to the garage in the dark, and it works a treat, so well chuffed.

Just waiting for the parts now, they were supposed to be here by now, but the dealer says that Yamaha are a bit behind with their deliveries. Rather narked, as I got a puncture in my scooter tyre at work, and I need my big bike up and running again so that I can get that repaired in the shop!

Mister James · I want to believe! Joined: 10 Aug 2004 Karma :

Perfect. The new tool worked a treat, and I managed to get all the fairings off and replaced. (apart from the one they forgot to order - d'oh)

However, I have found yet more stuff that needs doing. The footrest/rear brake bracket that I took off the bike has bushes installed in the holes - whereas the replacement one does not. I'm leaning towards getting my dealer to install those for me, is that a realistic approach?

Also, my handlebars have a slight bend in them, that I did not originally notice. Is it relatively easy to replace these, or is that going to be a dealer job as well?

Finally - the bar that supports the dash/fairing and connects it to the front of the bike frame is slightly bent to one side where the bike landed on it. Can that be bent back safely, or should it be replaced.

I'm sure I'll have some more moronic questions for you at some point soon Smile