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Discussion Starter · #1 ·
Ok so really I just want to vent, I´ve read all the threads on here about the problem and solutions but I´ve got a bit of a long story about this particular problem.

It all started in Honduras. Riding to the Nicaragua border I suddenly heard a noise of epic proportions coming from the output shaft. You guessed it, dead splines. After a day or two of umming and ahhing with a border town mechanic I decided to get it welded on. There seemed to be no other option. The enxt day I ordered a new shaft, sprocket and gaskets. I was lucky to have a friend who was visiting costa rica and she brought them all out for me.

Fast forward a month and I´ve got the parts, found a recommended mechanic and set in motion the whole process. Rode the bike up and was told it would take 5 days tops so I stayed in a hotel, watched porn and basically wasted time. When the bike was finished it made an aweful knocking noise from the output shaft again. I couldn´t believe it. The mechanic said it was normal, we argued he eventually fixed it while bitching and moaning the whole time.

Alright, noise gone but now an odd vibration. I accepted it after reading about rebuilds and how the engine wont feel exactly the same afterwards. Ok, fast forward another couple of months to Colombia.

I meet with A guy who recommends a good mechanic who will let me use his tools. Brilliant, time to clean carbs, change oil etc etc. During the work I decided to test the compression. Almost half. Shit. Mechanic says it´s not a problem, theyhave all the parts there and can do it cheap. Valves and cylinders, brilliant, it´ll be like a new bike. They tore the engine down and then realised they didn´t have the parts. It took 2 months for them to arrive, two long boring months stuck in Medellin. We tried to make the most of it and Heather even got a job. Because it was taking so long I asked them to look at the output shaft to check everything was ok. Yeah, engines in great condition. Everything looks perfect apart from a slightly worn oil pump. Ok I´ll live. Get the bike back and guess what. The noise is back. Im out of time, my visa is about to expire and my insurance is running out. Mechanic tells me its fine as it only happens in neutral (turns out its not true) and only when the bike is leaned over (also not true) deciding we have no choice we head off to Ecuador. The bike rides horribly the whole way. Fifth gear is a no go as it causes odd vibrations and a clunking noise, first makes a loud buzzing noise if I use it too much.

Enter Diego. In Quito I meet up with Diego, a young guy who has his own workshop and is a suspension specialist. Out of money now so I decided that I was going to tear the engine down and fix it myself. This is a first for me. Most i´ve done before is rebuilding carbs and that scared the crap out of me. Diego briefs me on what to do he tells me I better be the most organised person in the world(i´m not) and take photos of everything. Partially because his workshop is so clean and partially because I was scared shitless I became the most organised person, box for front cylinder, box for rear, box for alternator and one for the clutch and one for the crankcase parts.

Engine out in day one, engine torn down by day two, day three we look at the output shaft and can clearly see the problem. The first gear is moving about way too much. It´s got a good mm of movementthat shouldn´t be there. So looking through the Haynes (buy one) I find the picture of my output shaft and start comparing everything eventually i notice the washer and circlip next to the first gear are the wrong way round leaving the first gear free to do what it wants which in this case means banging against bits that point sideways on the the third gear pinion.

I´m not relieved yet, the bikes still in peices as we ran into another problem, one of the rods in the crankcase which the cylinder and head slide over has stripped its thread in the crankcase (one of the previous mechanics had done this and I found it after rebuilding everything, yay) so on Monday it´s going to someone who can put a helicoil in. I´ll keep you updated on progress and post pictures later tonight but mostly I just wanted to rant.

I trusted these guys, I paid them a lot of money and lost a lot of time. They even had the haynes manual so they could look and see what the problem was but it took a numpty like me to actually go in and find the problem. I´ve been lied to, ripped off and had a large portion of an amazing trip ruined by people who just don´t give a shit about other people. If you have a good mechanic give him a hug, let him know you appreciate his ability and the effort he puts into keeping you on the road. When I get some free time I´m going to build a website called world mechanics. It´ll be a place to post a mechanics location, contact details and a full review. That´ll be my petty revenge. Hopefully it will reward the good mechanics and punish or shame the bad ones into being good.

Sorry for the long post, just had to get it off my chest, I´ve had my heart in my throat for the past few days as I´ve been working so need to let off some steam.
 

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The Angry Pasty Muncher
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6,170 Posts
I understand your frustration mate and understand where your coming from being pissed off like that, i would be aswell.
Just get an overview your ok and in good health even if the bike isn't keep the perspective that it's only nuts and bolts mate, it can be repaired or replaced. It's difficult finding people you can trust with your kit but sometimes you can't help but to use whoever is around at the time and it's hit and miss what the outcome can be.
 

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Discussion Starter · #3 ·
I´m looking on the bright side, I now know how to tear down an engine and rebuild it, hell by next week i will have done it twice! I wont ever go to a mechanic again. My time isn´t so valuable but my bike is.

Cheers for the support.
 

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80 Posts
Hi boomer84!
What's the make and year model of bike? Is it because you have you run with no-slack chain that splines are no good or dry chain?
 
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