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Mothers Mag and Aluminum Polish : https://www.homedepot.com/p/MOTHERS-10-oz-Mag-and-Aluminum-Polish-Paste-05101/321179405 Be forewarned, a ride thru wet, dirty streets WILL cause stains after polishing. So with that said, it is something to cntend woth once the heavy stuff is off. I keep...

There shouldn't be any creaking / cracking at all.... .

To add to Garys post, with what your describing, there SHOULD BE EVIDENCE OF SOMETHING RUBBING when tightening down the cover. .

The stator is attached using some SERIOUSLY strong locktite. (Use heat at the base of the crews to remove or you will strip the screw heads) As for it coming loose, no way, un-less someone was inside and barely snugged the bolts down... It was posted that the engine spun, y hand easily- I...

So, quote "Starter motor is good and spins strong on bench" (from first post). AND, you replaced with another known good starter?. Also, quote "and all electrical power drops (lights shut off when trying to crank)." sounds like the starter is drawing down all the power.. Did you ever do a...

Late to the party, but posting now from a recent "starting issue" post... Part 4, the brush / end cap is cheap enough (about $80.00) and OEM: https://www.partzilla.com/catalog/yamaha/motorcycle/2007/fz6-fzs6w/starting-motor The brushes do wear out and aren't difficult to change out. The TB's...

Just for S & Gs, remove the starter and pull the end cap(brush end) off. Inspect for worn brushes. I know you did a bench test (no load), but I strongly suspect a bad starter.. A rusted Sprague, inside the engine, doubtful... Also, what's the mileage on the bike? From my '07 with about...

To add to Toms post, both hoses should exit on the right side of the bike, about where the center stand (and O2 sensor if installed) is. You can feel thru the frame, for the hoses and gently tug them out. The inside of the tank, the vent and over flow lines:

Mine has the rubber (upper) inserts on all the pegs as well... I suspect the other bike has aftermarket pegs.. .

Put a hold / dispute immediately on the credit card. Doesn't cost anything, save all your e-mails, etc to forward to your CC company . .

Ok, that makes sense, no ABS in the US. Great info!!

Perhaps /apparently, it's different between the US bikes and European bikes. That or possibly your bike was built in a "change over(not the correct wording) . Yours is the first S1 bike I've seen with the tank NOT under the seat... Interesting! .

My '07 expansion tank is behind the header. The S1's overflow tank is UNDER the seat. The rest is correct... The op's bike is an S1, no doubt...

The welded, passenger foot pegs are also ONLY on the S1. It's an S1..

Make sure the two vent lines, attached to the underside of the tank, are not kinked. When ever the tank is raised and then set back down, those hoses will kink. (Possibly causing the tank to not vent-running out of fuel with full tank) The fuller the tank, the worse it would be. Just reach...

Just a reminder about old, un-treated, E fuel... :( This week from a customers 2005 Harley Wide Glide (with a CV40 carb) that came in for a carb clean / get running. It'd run on starting fluid only.. Fuel was reportedly 1 year old, (Chinese knock off carb), un treated... Besides the "Gelled"...

Sounds like the pump needs cleaning or replacement.. Fuel pump failure is not un-common, especially for machines that sit awhile, etc.. Quantum has reportedly a good reputation (as posted here): https://www.highflowfuel.com/fuel-pump-oem-replacement-hfp-382-y-qfs/

Check battery voltage at the battery when it's running. It should be close to 14 volts... .

Probably not part of your issue HOWEVER, the handle bar KILL SWITCH is a known issue for failure. It's been documented, NOT to use that switch (un-less an emergency) as regular use leads to failure.. IE, leave the switch in the RUN POSITION, always.... Just turn the bike on and off by THE...

As a refresher, anyone wanting info on the original BD43 mod, the link: https://www.600riders.com/threads/bd43s-07-headlight-mod-part-1.1663/ .