06 Re-assembly after low-side

[K-2]

After 9 weeks at the dealer (mostly waiting for back-ordered parts from Yamaha), I finally pickup up my partially repaired 06 after my Memorial Day low-side (see thread link below). I'm taking the bike on a 1500 mile trip this coming week and asked the dealer to put my damaged mirror back on while we continue to wait for the new one.

Here is my question, the re-build of the cowling, fairings, etc does not look right at all. Everything is slightly shifted to the right, there are gaps between panels that never existed from the factory, etc. How hard is it to put this bike back together with factory-quality fit and finish? I won't be satisfied until it looks like it has never been down.

Any thoughts from those of you that know how all this stuff goes together?

Post Thread of Low Side Event

 

[Howardrg]

The dealer has fitted the tupperware onto supports/brackets that are out of alignment, is my guess.

Make arrangements to take it back after your trip.

You should then point out the parts/pieces that you are unhappy with. Best is to have another 06 next to yours when the job is done.

I would have something to say to the shop foreman for not checking the work.

Howard

 

[teerex51]

The dealer has fitted the tupperware onto supports/brackets that are out of alignment, is my guess.Howard

K-2

I agree with Howard.

Most likely your subframe is bent (I recall my original post back when you had your low-sider: I was then hoping the damage would not extend beyond the scuffed tupperware).

Having experienced the same problem when rebuilding my own bike, I would say they need to take the front cowling apart and replace the metal subframe circled in red above. I don't think they did before putting the new parts on.

Stef

 

[K-2]

Thanks, Stef.

Here is the replaced part list from my invoice. Do any of these match the subframe piece you suspect is bent?

3P6-15411-00-00 COVER, CRANKCASE 86.08

5JW-15451-10-00 GASKET, CRANKCASE 9.32

3P6-21511-00-P2 FENDER, FRONT 88.84

3P6-W283G-00-P2 UPPER COWLING ASSY 137.16

3P6-28356-00-00 STAY 285.82

3P6-Y283J-30-P2 BODY, FRONT LOWER 379.13

There are other parts related to side bag, kickstands, footrest, clutch lever, etc. But the ones above appear to be the bulk of the front-end related parts.

 

[teerex51]

Do any of these match the subframe piece you suspect is bent?
3P6-15411-00-00 COVER, CRANKCASE 86.08

5JW-15451-10-00 GASKET, CRANKCASE 9.32

3P6-21511-00-P2 FENDER, FRONT 88.84

3P6-W283G-00-P2 UPPER COWLING ASSY 137.16

3P6-28356-00-00 STAY 285.82

3P6-Y283J-30-P2 BODY, FRONT LOWER 379.13

K-2

Yep. There it is. They did charge you for the sub-frame (a "stay" in Yamaha-speak) but then they'll have to explain why the bike's front cowling still looks off-kilter.

I am sorry, bro, but you will need to have a good talk with them about this. There's no reason why (assuming the "stay" has indeed been replaced) the various fairing parts should not fit together perfectly now.

Stef

 

[slapnpop]

This is *some* adjustment of the plastic peices in simply how loosely they fit together. If all parts are off in the same direction, I would suspect subfrome too. How much of a gap are we talking?

 

[K-2]

Here are some examples picture the various gaps. Additionally, the reveal on either side of the tank indicates a shift of the whole front-end to the right. When I pointed that out, the mechanic adjusted the tank position to counter the reveal - I'm not convinced that's the correct fix. It is tough to eyeball this stuff, but I'd swear there is not a perfect vertical/straight line running from the tip of the front fender, through the dead-center of the headlights, back to the ingition key, etc.

 

[slapnpop]

That small of gap could probably adjusted out. Try loosening the screws of a joint slightly, and holding the panels in proper alignment, and tightening the screws back down. The tank also has a bit of plat at the front.

 

[MotorSWATCop]

I wouldn't accept it and I wouldn't do the work myself. The dealer said he could repair it; he should. Otherwise, get him to declare it totalled and get a new one. It it passible that there is damage to the frame itself?

 

[K-2]

I can't imagine the frame itself is bent. I was only going about 15mph when I slid the rear tire out from under me. Granted, it was not a smooth fall...the bike and I rather slapped into the pavement as I fought to avoid a high-side. But frame-bending it should not have been. Someone around here posted a video of himself going down in a turn (recently repaired and now posting videos again). His bike was damaged far worse than mine.

 

[teerex51]

I wouldn't accept it and I wouldn't do the work myself

Absolutely not. Like MotorSWATcop said, let them deal with it.

Stef

 

[06FJRAEPILOT]

After 9 weeks at the dealer (mostly waiting for back-ordered parts from Yamaha), I finally pickup up my partially repaired 06 after my Memorial Day low-side (see thread link below). I'm taking the bike on a 1500 mile trip this coming week and asked the dealer to put my damaged mirror back on while we continue to wait for the new one.
Here is my question, the re-build of the cowling, fairings, etc does not look right at all. Everything is slightly shifted to the right, there are gaps between panels that never existed from the factory, etc. How hard is it to put this bike back together with factory-quality fit and finish? I won't be satisfied until it looks like it has never been down.

Any thoughts from those of you that know how all this stuff goes together?

Post Thread of Low Side Event

If you want it done right, do it yourself!! I put an 05 back together in a shade over a month. Three separate parts orders slowed the process some, but I wasn't in a big hurry as I had a spare bike. Ordered the parts from Gary in Fargo, North Dakota at a pretty good discount. Everything fit like a glove ( just know if you have to force it, it isn't right), and I knew that every screw, bolt and fastner was in place and all that required torque had been done properly. It isn't that difficult to do. You may have to get some job specific tools that are mostly available at Sears. Bottom line is you will know what you have when your done! You won't be saying I wonder if he tightened this or that! Or are all the screws/fastners installed. If they are not, when you do the work, at least you will know that no one else screwed up but you.

I can't imagine the frame itself is bent. I was only going about 15mph when I slid the rear tire out from under me. Granted, it was not a smooth fall...the bike and I rather slapped into the pavement as I fought to avoid a high-side. But frame-bending it should not have been. Someone around here posted a video of himself going down in a turn (recently repaired and now posting videos again). His bike was damaged far worse than mine.

Often the number 1 stay will bend. It is attached to the main frame with two bolts and is easily removed and replaced. This stay, in addition to providing a place to hang relays, is responsible for the alignment of the front cowl & instrument panel which if not properly aligned can have an adverse impact on how the side farings fit. The number 1 stay is designed to bend and in an impact it will do just that.

 

[Hotboot]

I am debating repairing all my plastics myself, how hard can it be doing all the tupperware, bags, levers and exhaust cans. I just need a dealer estimate to get a dollar amount for insurance purposes.

 

[Dan23]

My '06's dash looks exactly like yours and has from day 1.

Are you sure this is new?

 

[weekend rider]

Befor e you accept your bike you better note everything that is wrong take pics and have the dealer or service manager sign and agree that you will bring it back after tour trip. If you don't you are in for a big challenge trying to get them to repair it, after all time is money for them and they don't care.

If you think the above reply is bullshit than dont do it weekend ridere

 

[K-2]

My '06's dash looks exactly like yours and has from day 1.

I wasn't expecting a revival of this thread, so I never have updated it. The dealer gladly took the bike back after my trip and make every effort to satisfy my complaints. They did the best the could after several attempts over 3 days, and I still wasn't quite pleased. Before complaining again, I walked around the corner and checked out a new 06 on the showroom floor...as Dan23 said, some of these poor-fitting parts are coming that way from the factory. The new 06 was no better than the final version of my repairs. Must be some inconsistency in parts manufacturing - I do know many of these gaps were not present on my bike originally, and yet a later 06 still on the floor has gaps just like my newly replaced parts. Oh well. I'm over it, and very glad to back on my beautiful blue machine!

Thanks for all the help! This forum rocks...

 

[weekend rider]

K2 All of mine on the 05 fit very well gaps are good close. But you are happy so on with riding that beast.

That was a good try from your dealer he did more than most +1