PICTURES: (ENGINE ON THE FLOOR..!!) .....eeek!!

[steelboss]

Hi all...
Back in November 2014 my second gear went belly up and I could not use it at all. I had to ride shifting from 1st to 3rd and that can be dangerous when you forget. At the same time I was having bad luck with aftermarket grips, because the cable connections break. Anyway, back to the engine. In China I am limited for mechanics, but I have an excellent one.
After Warp gave me the advise to contact Andy at North county Yamaha a e-mail andy@ncyyamaha.com and explain my problems, i did so and was sent the 2nd gear overhaul kit. I was afraid to see my motor on the floor, but I had no choice. My mechanic cannot read English so he stored the engine manual in a broken washing machine so it would not get lost and never looked at it again.
This guy has a tiny shop with only a few tools, half of which are made by himself...seriously. But I have to follow him or park the bike. I refused to go there while he worked on my bike because I just couldn't watch. I went only one time and took the pics here. He took 3 days to finish but he also services about 20-30 other bikes every day.
After the bike was returned to me it first seemed very tight to find the gears, but in a couple of days it was just perfect. My rocket just hits all gears dead-on and responds just like a new bike. We changed the clutch discs at the same time...and the OEM grip. I am really please at the result. Thanks to Warp, Hanso, Peter K, Gregger, Idaho Red, Scorp, all u guys who offer inspiration.

 

[CanberraR3]

Great pics and nice write up. Glad you're up and running.

 

[warp9.9]

Hi all...
Back in November 2014 my second gear went belly up and I could not use it at all. I had to ride shifting from 1st to 3rd and that can be dangerous when you forget. At the same time I was having bad luck with aftermarket grips, because the cable connections break. Anyway, back to the engine. In China I am limited for mechanics, but I have an excellent one.
After Warp gave me the advise to contact Andy at North county Yamaha a e-mail andy@ncyyamaha.com and explain my problems, i did so and was sent the 2nd gear overhaul kit. I was afraid to see my motor on the floor, but I had no choice. My mechanic cannot read English so he stored the engine manual in a broken washing machine so it would not get lost and never looked at it again.
This guy has a tiny shop with only a few tools, half of which are made by himself...seriously. But I have to follow him or park the bike. I refused to go there while he worked on my bike because I just couldn't watch. I went only one time and took the pics here. He took 3 days to finish but he also services about 20-30 other bikes every day.
After the bike was returned to me it first seemed very tight to find the gears, but in a couple of days it was just perfect. My rocket just hits all gears dead-on and responds just like a new bike. We changed the clutch discs at the same time...and the OEM grip. I am really please at the result. Thanks to Warp, Hanso, Peter K, Gregger, Idaho Red, Scorp, all u guys who offer inspiration.

Great to see she is back up and running and your enjoying the torque again !!!!!

 

[Ugarte]

Great pics, thanks!

He did all that without a manual? How did he know the proper torque numbers or did he even have a torque wrench?

Glad it worked out and you are back on the road again.

 

[2012cliff]

Hi all...
Back in November 2014 my second gear went belly up and I could not use it at all. I had to ride shifting from 1st to 3rd and that can be dangerous when you forget. At the same time I was having bad luck with aftermarket grips, because the cable connections break. Anyway, back to the engine. In China I am limited for mechanics, but I have an excellent one.
After Warp gave me the advise to contact Andy at North county Yamaha a e-mail andy@ncyyamaha.com and explain my problems, i did so and was sent the 2nd gear overhaul kit. I was afraid to see my motor on the floor, but I had no choice. My mechanic cannot read English so he stored the engine manual in a broken washing machine so it would not get lost and never looked at it again.
This guy has a tiny shop with only a few tools, half of which are made by himself...seriously. But I have to follow him or park the bike. I refused to go there while he worked on my bike because I just couldn't watch. I went only one time and took the pics here. He took 3 days to finish but he also services about 20-30 other bikes every day.
After the bike was returned to me it first seemed very tight to find the gears, but in a couple of days it was just perfect. My rocket just hits all gears dead-on and responds just like a new bike. We changed the clutch discs at the same time...and the OEM grip. I am really please at the result. Thanks to Warp, Hanso, Peter K, Gregger, Idaho Red, Scorp, all u guys who offer inspiration.

 

[2012cliff]

It is really interesting to have a brief view into another mans shop. It is fascinating to try to find this guys tools or lack of, in the pictures. What a mechanic has to work with and what he might have to manufacture to get the job done. ( this ain't no dealership shop) my shops a mess and when i need a special tool i'll google it and try to make it or go buy one.

 

[idk]

I'm glad that it is all up and running again. Sometimes those sort of mechanics are the best. Hopefully the bolt which needs the special locktite was done correctly.

 

[steelboss]

It is really interesting to have a brief view into another mans shop. It is fascinating to try to find this guys tools or lack of, in the pictures. What a mechanic has to work with and what he might have to manufacture to get the job done. ( this ain't no dealership shop) my shops a mess and when i need a special tool i'll google it and try to make it or go buy one.

Cliff, this guy is an absolute wizard. He led cross-country bike tours for almost 30 years and was fixing bikes all the time and now he only works on bikes. I have been taking bikes to him for 5 years and I have seen everything imaginable stripped down on his floor. I have watched him make tools several times. Indians, Harleys, all types of Super sportbikes, cruisers, whatever. He serviced my Ninja for 2 years. Granted he has vacuum tools and meters, etc., but he is just a pure mechanic. The best part is he is open until 9pm.

 

[1olbull]

WOW!
What an odyssey and great story!

 

[forklift]

Hi all...
Back in November 2014 my second gear went belly up and I could not use it at all. I had to ride shifting from 1st to 3rd and that can be dangerous when you forget. At the same time I was having bad luck with aftermarket grips, because the cable connections break. Anyway, back to the engine. In China I am limited for mechanics, but I have an excellent one.
After Warp gave me the advise to contact Andy at North county Yamaha a e-mail andy@ncyyamaha.com and explain my problems, i did so and was sent the 2nd gear overhaul kit. I was afraid to see my motor on the floor, but I had no choice. My mechanic cannot read English so he stored the engine manual in a broken washing machine so it would not get lost and never looked at it again.
This guy has a tiny shop with only a few tools, half of which are made by himself...seriously. But I have to follow him or park the bike. I refused to go there while he worked on my bike because I just couldn't watch. I went only one time and took the pics here. He took 3 days to finish but he also services about 20-30 other bikes every day.
After the bike was returned to me it first seemed very tight to find the gears, but in a couple of days it was just perfect. My rocket just hits all gears dead-on and responds just like a new bike. We changed the clutch discs at the same time...and the OEM grip. I am really please at the result. Thanks to Warp, Hanso, Peter K, Gregger, Idaho Red, Scorp, all u guys who offer inspiration.

on the bottom picture I'll bet that little sign on the wall with a policeman says "Labor rate 500 yuan per hour".
IF you help 1000 yuan per hour.
And the second line probably says "You want it when???"