My bike has had a rattle recently that's become rather chronic so I spent today going over it to find the cause. As soon as the engine warmed up it would start tapping and the hotter it got the worse it got. Turns out that on the right cylinder 3 of the 4 pushrod ends were loose. The three ends had been clacking so much they had worn the end of the pushrod tube down slightly which caused the clearances to open up to twice what they should be.
I pulled the ends out with pliers but had to heat up the tube to pull the fourth. Then I took some quick measurements of the tube.
Simple enough to make so I got some 600 series ally and turned new tubes. Here is the end of my new tube compared to the old one. You can see where the end ball had sunk into the tube a bit
The ends stalks are 4.68mm so I figured I would drill and ream 4.5mm and press them in. Here's a quick test fit.
I made a quick jig to protect the ball, not that it needs it as it's hardened but you need to be sure. Pressed the ends in using my tailstock ram.
Two new rods next to the old one.
I checked the LH cylinder and those ones were still firmly fitted so I left them alone. I put the lot back together and set the clearances and it's now back to a satisfying rustle when running instead of a horrible rattle.
New pushrods
Moderators: Gromit, Paul, slparry
Re: New pushrods
Well done, I'm always impressed when someone has the skills and equipment to solve problems like that!
Ian
Ian
Motorrad R1250RS SE 2023
Blue R100RS 1980
Suzuki GT250B 1977
Blue R100RS 1980
Suzuki GT250B 1977
Re: New pushrods
Sweet
R11s + Val Singleton Power filter - Lennies induct - Y Piece - Wilbers - PC111
1974 Honda CB750 1974 Triumph Trident T150 Oh and a GS-LC
1974 Honda CB750 1974 Triumph Trident T150 Oh and a GS-LC
Re: New pushrods
Nice work ! for those who don't have the ability the OE replacements are one piece. I did replace mine years ago but the engine still rattles over 60k miles later...
_________________
Nigel
Keep smiling, it makes people wonder what you've been up to!
1999 R1100s (mandarin) '
2018 DL 250V Strom
2019 CB125F Honda.
MZ301 Saxon Fun ( currently retired)
'03 Bullet 65 project..
Nigel
Keep smiling, it makes people wonder what you've been up to!
1999 R1100s (mandarin) '
2018 DL 250V Strom
2019 CB125F Honda.
MZ301 Saxon Fun ( currently retired)
'03 Bullet 65 project..
Re: New pushrods
Thanks guys. I'm on 88k miles so it's not done too bad. I knew that I could get one-piece replacements but having the tools and the inclination I preferred to just make some new ones.
The one-piece jobs must be all steel I guess?
The one-piece jobs must be all steel I guess?
Re: New pushrods
Pete. wrote:.
The one-piece jobs must be all steel I guess?
Yup
_________________
Nigel
Keep smiling, it makes people wonder what you've been up to!
1999 R1100s (mandarin) '
2018 DL 250V Strom
2019 CB125F Honda.
MZ301 Saxon Fun ( currently retired)
'03 Bullet 65 project..
Nigel
Keep smiling, it makes people wonder what you've been up to!
1999 R1100s (mandarin) '
2018 DL 250V Strom
2019 CB125F Honda.
MZ301 Saxon Fun ( currently retired)
'03 Bullet 65 project..
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Re: New pushrods
Great post. Love these diy fixes.
Chris
Chris
Fiat Panda.
Fiat Scudo (with speedblock, pipe carrier, reversing sensors, reversing camera, tow bar, some new rust and Fake Plumber logo)
started out with nothing, still have most of it left.
Fiat Scudo (with speedblock, pipe carrier, reversing sensors, reversing camera, tow bar, some new rust and Fake Plumber logo)
started out with nothing, still have most of it left.
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