The crash damage and the rebuild (pic heavy)

[J.M.]

So first of all I'll link you to the crash thread (linky).

The TL;DR is that I crashed in to a van, with me at fault. Below is the aftermath of the crash and the slow rebuild of the bike. I aimed to do it as cheaply as possible, bodging as much of it as possible. I think the total cost was under £300. I could more than likely have gotten it cheaper but I needed to get the bike back on the road as soon as possible. The photos below detail over a month from the first picture (taken on the day of the crash) to the final picture (taken at the MAG Demo).

I still need to put some mirrors on the bike, though, I've done a few hundred mirrorless miles now and I'm not missing them at all.

Here goes, a hell of a lot of photos.

1:
Here we can see the physical damage to the wheel.
https://photos-h.ak.fbcdn.net/hphotos-ak-ash3/581051_411232665578369_935089189_n.jpg

2:
Somehow I managed to crack the wheel itself. Not just crack it though, the thing bent rather a lot too, which is visible if you try and marry the parts together (not visible in this photo).
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/536655_411232862245016_672277859_n.jpg

3:
And just another shot of the wheel damage.
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/547136_411233198911649_1060257628_n.jpg

4:
Pictured here is the bike with the fairings and front wheel removed. The bike is sitting on the centre stand with a few wooden blocks under the exhaust pipes so that it doesn't tip forwards. There isn't much weight on the blocks so there wasn't really any risk of damaging the pipes. The forks don't look too bad in this photo. They're gone though.
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/525119_411233435578292_1799070632_n.jpg

5:
Then we have the removed fairings (from 5-11). From a distance they really (surprisingly) don't look very bad from this distance. There's a few cracks and such illustrated below but it's really not too bad.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/560256_411233542244948_1264854678_n.jpg

6:
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-prn1/543296_411233565578279_622809908_n.jpg

7:
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/389580_411233598911609_1818390772_n.jpg

8:
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/536061_411233658911603_1288271518_n.jpg

9:
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/75258_411233722244930_1494174399_n.jpg

10:
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-prn1/538239_411233762244926_1236352509_n.jpg

11:
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/318281_411233802244922_486010039_n.jpg

12:
You're now looking at the front mudguard. When the bike hit the van, the forks obviously bent inwards and this led the back of the mudguard to hit in to the exhaust pipes, melting the mudguard.
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/310037_411233852244917_1646377276_n.jpg

13:
The next few images illustrate the fork damage to the bike - i.e. they're bent.
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/534195_411233965578239_334432970_n.jpg

14:
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/540666_411234092244893_602421326_n.jpg

15:
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc7/156254_411234182244884_794309332_n.jpg

16:
After removing the forks from the yokes, it's apparent that they're actually creased. Not a hope in hell of getting those straightened.
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/148993_411234298911539_261029069_n.jpg

17:
Pictured below is the bike with no forks/front wheel/fairings.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/579834_411783485523287_1281617484_n.jpg

18:
Then without the fuel tank.
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/398952_411783945523241_650911288_n.jpg

19:
Again without the fuel tank from another angle.
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/532719_411784258856543_1748319111_n.jpg

20:
And finally with the rear fairings removed too. I thought that with the bike in so many bits, I may as well take this opportunity to take the rear fairings off and give them a good clean on the inside considering how dirty they were.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/165797_411784495523186_1891537684_n.jpg

21:
Now for the alarm. A Cyclone V2, but the wires are much too short for the new location that I have in mind for it. I simply cut the wires leading from it in half and soldered on my own wires inbetween so that the wires were now the length that I needed.
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/181387_418078641560438_1623096787_n.jpg

22:
Here you can see what I described in 21 is finished.
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/181387_418078654893770_1290941042_n.jpg

23:
This is the rear fairing, all cleaned up on the inside ready to go back on the bike.
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/542469_419075201460782_1509132289_n.jpg

24:
Seat, rear fairings and fuel tank have all been fitted again, along with my Cyclone V2 which has been relocated in an inaccessible and well hidden position. The siren has also been moved to a location which is more audible and harder to access. The kind of harder to access where it's a right pain to even place it there, then you've got all of the fairings to obscure it too.
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/554704_419075324794103_365844270_n.jpg

25:
A close-up of the brake calliper at the front, sitting upon what's left of a carlsburg box. I never realised that resetting the pistons was such a pain to do.
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/554716_419075471460755_1628921936_n.jpg

26:
Pictured here are the new forks and wheel sitting astride the old forks and old wheel. The new forks are from the older version of my bike, though they are thankfully all interchangeable.
The forks cost me £120 and the wheel cost me £60 with a usable tyre (though needs replacing, I've done a few hundred miles on it already though). The wheel was a little expensive, though I knew that with these two parts I could "illegally" take my bike out for a spin. I say illegally because there was no tax disk/front mud guard/temperamental indicators/headlight/very bent handlebars/etc. Was fun though.
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-snc7/292634_419294348105534_1861271049_n.jpg

27:
The brake disk, ready to go back on the bike.
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/601468_419294941438808_1389348157_n.jpg

28:
Another shot of it, don't know why.
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/389308_419295334772102_322304517_n.jpg

29:
The forks fitted to the bike. This was a complete pain to do because they weren't locating properly through the top yoke and the bottom yoke. In the top yoke they were around 1cm off. (If you located one, the other would be off).
I solved this by locating them in the top yoke and then sliding the bottom yoke up the forks in to position, finally tightening the nut up on the top yoke to pull it all tight and in to position.
The eagle-eyed of you will notice that the forks are on the incorrect way round. The brake calliper goes on the right hand side of the bike, you can clearly see the mount for the brake calliper on the left in this image. Yep, got to do it again.
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/148785_419295784772057_1074908050_n.jpg

30:
Finally with the new front wheel installed, forks installed, brake calliper back on and generally the front end back together in full working order.
I took it for a ride like this, in it's current state. I didn't even check the PSI on the front tyre before going; simply "eh, looks okay, I want to ride! "
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc7/578324_419296248105344_647043959_n.jpg

31:
So here it is pictured after the said ride out. I covered just a few miles nipping to the bike shop to grab myself an indicator bulb. I made my way there, through town, with no indicators. Sticking to the cager's principle though "who needs 'em!"
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/270956_419952881373014_1234681678_n.jpg

32:
Hard to see in this image, but the rear of the mudguard has been cleaned up. By cleaned up I mean that I cut off the mangled bit with a saw and then used some sand paper to round it all off and make it look neat again.
The mudguard plate is in a visibly bad condition and all of the bolts rounded upon trying to remove them.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-prn1/551018_422796797755289_640061985_n.jpg

33:
I went for another ride, this time to the petrol station. Pictured below is where I ran out of fuel, so I thought to grab a few photos whilst waiting on a jerry can.
Note to self: spirited rides whilst running on fumes are not advised.
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc7/318260_422797151088587_668645575_n.jpg

34:
Upon stopping, I realised that I had also not done up the pinch bolts in the upper or lower yoke. One of the pinch bolts is now missing. I did the others up hand tight whilst feeling like a moron.
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/292559_422797461088556_40984967_n.jpg

35:
Once back home again I removed the handlebars. They really are unusable. You can't even get half lock whilst turning right.
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/526682_422797641088538_301472570_n.jpg

36:
Handlebars: Left side normal, right side bent.
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/600899_422797907755178_586490772_n.jpg

37:
Now it's time for some bodging. I'm going to attempt to melt the plastic fairings back together. I'll be using the plastic tub (pictured) to cut up and melt over the cracks.
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/564198_426090180759284_1335902844_n.jpg

38:
Pictured here is the first crack I will attempt to do.
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/534433_426090404092595_1903656922_n.jpg

39:
First of all: Gaffer tape on the outside to hold the fairing in position.
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-prn1/564327_426090580759244_639843369_n.jpg

40:
Use said soldering iron and plastic tub to melt over the crack and generally melt the plastic back together.
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/223807_426090767425892_981763513_n.jpg

41:
What I said above, just completed.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/600687_426090894092546_1371150512_n.jpg

42:
With the gaffer tape removed, you can see that the fairing is now repaired and back in the proper position.
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/481152_426091004092535_1159917023_n.jpgp

43:
Though, I covered the inside with gaffer tape still to add some strength to it, theoretically.
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/575117_426091110759191_1131806692_n.jpg

44:
Same job again: cracked fairing, repair it.
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/543198_426091220759180_1234942838_n.jpg

45:
The above fairing, repaired.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/181100_426091350759167_1340811384_n.jpg

46:
Mocking up the panels 1 of 3.
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/526172_426091507425818_1046315712_n.jpg

47:
Mocking up the panels 2 of 3.
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/545565_426091644092471_1185632509_n.jpg

48:
Mocking up the panels 3 of 3.
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/167412_426091820759120_543952458_n.jpg

49:
Here's the nose cone. The headlight unit is slightly broken, so I'll remove that and fix it too.
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/252347_426092027425766_166848752_n.jpg

50:
Also, new brake lever arrived!
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/551091_426092167425752_587523137_n.jpg

51:
Headlight assembly removed.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-prn1/527832_426092360759066_1261692052_n.jpg

52:
Broken part 1, needs to be fixed.
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/599410_426092534092382_1459097914_n.jpg

53:
And fixed. Not too bad I don't think!
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/545055_426092650759037_1734576866_n.jpg

54:
And the other side broke too. Fixed that too.
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/250675_426092797425689_872083555_n.jpg

55:
The unit now fixed. The camera flash makes it look like it's on!
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/318257_426092927425676_1173747066_n.jpg

56:
The fairings and front nose cone are now back on. Unfortunately I didn't realise that the inside trim needs to go on before the side fairings. This means the side fairings have to come off again. Also, no handlebars yet!
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/318079_426093054092330_795041526_n.jpg

57:
Or mirrors.
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/581225_426093177425651_2001186052_n.jpg

58:
The new handlebars arrived shortly. They cost about £20-25 from eBay. They're much straighter and wider than my original handlebars. It enforces a much more upright riding position, but strangely I actually find getting down with my chin to the tank much more comfortable now. Maybe it's because I have broad shoulders, I have no idea though.
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/523621_426093377425631_2122540199_n.jpg

59:
Here they are unwrapped.
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/314187_426093497425619_1358334199_n.jpg

60:
And fitted. Since this photo they have been moved slightly. In that position the nose cone was getting in the way and not allowing me to get full lock either way. Tilting them the other way however (so the horizontal bar running across is sitting on the other side of the yoke clamps) solves the problem perfectly. Full lock either side; not a problem.
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/525969_426093674092268_1555799868_n.jpg

61:
From the front: Handlebars installed, nose cone on, side fairings off.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/255468_426093854092250_2132636948_n.jpg

62:
Same again except now with the trim installed, the side fairings installed and the bar ends installed.
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/556397_426093970758905_1001699373_n.jpg

63:
Same photo from the front.
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash3/556287_426094080758894_1758840507_n.jpg

64:
Took the bike out for a late night spin after that and after an argument with the... now ex. Almost killed a rabbit. Almost shat myself. All okay though. Still not checked that PSI yet. I'm in for a shock when I do; 24 instead of 36.
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/318264_426094244092211_1152531546_n.jpg

65:
I attempted to take it out the next morning because I needed to get to college. The bike wouldn't start; there was no fuel getting to the engine. I also ran my battery flat several times; it's gone too.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-prn1/538618_431365586898410_206377989_n.jpg

66:
You can see a fair amount of petrol leaking out of the airbox. I turned the tap off under the tank but the bike kept leaking. At this point I didn't know where it was leaking from.
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/403378_431365783565057_425973710_n.jpg

67:
From here until photo 87 are simply carb-removal photos. I took them mainly for reference for when I put it all back together (hence why pipes have been drawn on to label them). I don't think the next few photos need labelling.
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-prn1/547153_431365980231704_1981405836_n.jpg

68:
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/206202_431366116898357_983601225_n.jpg

69:
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-prn1/532861_431366303565005_521468501_n.jpg

70:
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-prn1/534448_431366446898324_767928093_n.jpg

71:
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/534201_431366583564977_152682651_n.jpg

72:
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-snc6/252218_431366760231626_776596519_n.jpg

73:
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/165991_431366946898274_345600325_n.jpg

74:
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/598562_431367090231593_1225271662_n.jpg

75:
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/196025_431367240231578_2131537189_n.jpg

76:
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-prn1/542499_431367420231560_806600373_n.jpg

77:
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/401968_431367530231549_149688428_n.jpg

78:
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/554800_431367706898198_1864310892_n.jpg

79:
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash4/229886_431367893564846_1150411173_n.jpg

80:
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/285729_431368080231494_753097610_n.jpg

81:
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-ash3/579934_431368313564804_1644467563_n.jpg

82:
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/403464_431368560231446_814233736_n.jpg

83:
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/542522_431368746898094_1790049677_n.jpg

84:
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/179936_431368960231406_2115779602_n.jpg

85:
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-prn1/538491_431369166898052_628239055_n.jpg

86:
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/525771_431369480231354_972297634_n.jpg

87:
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc6/198403_431369830231319_1416281733_n.jpg

88:
Now, at this point you get to realise how much of an idiot I am. Stupidly for the first time ever when removing my fuel tank, I left it upside down for 2 entire days. Needless to say, it leaked a bit. Ruined my tankpad and was all inside the lock.
You can see here how I've removed the lock and it is in as many pieces as I can possible get it in to easily. I cleaned all of the parts, including the actual lock barrel, and put it back together. I also took the chance to check over all the seals.
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/421572_431370076897961_1283020123_n.jpg

90:
To stop anything falling inside of the petrol tank I placed some cling-film over the hole. I also theoretically assumed that it would also stop the kitchen smelling of petrol.
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc6/166066_431370246897944_1302518915_n.jpg

91:
Here is the lock in its rebuilt state.
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash3/554683_431370483564587_94968281_n.jpg

92:
Then put back inside of the casing (or whatever you call it).
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/575796_431370666897902_1216447968_n.jpg

93:
And finally installed back on to the petrol tank.
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/251921_431370856897883_880749954_n.jpg

94:
Earlier on I was removing the carbs. There are the 4 photos that I posted in the workshop asking for help:
1/4
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/550747_431371006897868_1291800498_n.jpg

95:
2/4
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-prn1/533288_431371206897848_2139059665_n.jpg

96:
3/4
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash3/598800_431371433564492_570294553_n.jpg

97:
4/4
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-prn1/543259_431371610231141_454107114_n.jpg

98:
And the guts of the bike with no petrol tank, carbs or airbox.
I also took cling-film and placed it over the top of any exposed pipes and then zip-tied it on. I figure that this way it will ensure that nothing dirt wise falls inside of any of the pipes.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash4/252378_431371826897786_288934067_n.jpg

99:
My lovely restrictors.
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/552971_431372013564434_207271206_n.jpg

100:
Somehow, they didn't fall out.
https://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc6/269242_431372243564411_1815165891_n.jpg

101:
Almost done now. Here's the front wheel with no mudguard or mudguard plate.
https://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/403433_431372426897726_436364422_n.jpg

102:
I managed to remove the plate by angle-grinding the bolts off. I then cleaned up the metal, repainted it and once my new bolts arrived I installed it back on.
https://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc6/180203_431372586897710_917223472_n.jpg

103:
You may notice how the wheel spindle is currently through the forks. I just did this so that I was sure the forks were located correctly when putting on the mudguard plate.
https://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash3/534252_431372793564356_1011471393_n.jpg

104:
My carbs arrived back, all lovely and clean.
https://a7.sphotos.ak.fbcdn.net/hphotos-ak-ash3/181172_431372900231012_1823361382_n.jpg

105:
Unfortunately one of the nozzles broke during postage. It was an easy fix though. I melted over the old hole ensuring that it was fully watertight and fully secure. Then I used a small drill bit to drill through the other nozzle and make a hole in it. I refer to the other nozzle as a nozzle very lightly as it didn't function. It was simply a bit of plastic which did nothing. Now it does something!
https://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash3/182315_431373060230996_672590804_n.jpg

106:
Pipes are starting to be installed on the carbs and they're going back in to the bike. You can see my lovely home-made fingerless gloves. Regular gloves, meet a pair of scissors.
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash3/542323_431373286897640_198108508_n.jpg

107:
Carbs installed, airbox installed, everything is back together except for the fuel tank.
https://a8.sphotos.ak.fbcdn.net/hphotos-ak-snc6/250621_431373453564290_158482055_n.jpg

TADA!

108:
24/06/2012, MAG Demo ride. I was able to attend and I have to say, I don't think she looks too bad!
Notable things are: gaffer tape on belly, no mirrors and tape on the engine. She ran perfectly though and I hit 110 again on the way home!
https://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/282363_438060082895627_1045627335_n.jpg
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2004 R1 & 2018 XSR900

[woll]

From the pictures it's evident you didn't try hard enough. You fail at crashing
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Current Bike- Suzuki DRZ400 SM K6
Previous bikes - Derbi Senda Xtreme50r, Honda CBR 125, Kawasaki ZZR 250, Yamaha DT125R, Suzuki Bandit 600, Gas gas ec 250, Honda CBR600FW
Damaged spleen, damaged kindey, 2 popped lungs, 2 broken ribs, broken face, broken wrist and 5 back fractures... remember kids walls hurt

[J.M.]

[CaNsA]

A bit of a "write up" wouldnt go a miss....

[J.M.]