New pushrods

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Pete.
Posts: 188
Joined: Thu Apr 02, 2015 7:16 pm

New pushrods

Postby Pete. » Sat Feb 08, 2020 11:15 pm

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.

Pushrods01.jpg
Pushrods01.jpg (136.3 KiB) Viewed 2030 times


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

Pushrods02.jpg
Pushrods02.jpg (123.47 KiB) Viewed 2030 times


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.

Pushrods03.jpg
Pushrods03.jpg (133.58 KiB) Viewed 2030 times


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.

Pushrods04.jpg
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Pushrods05.jpg
Pushrods05.jpg (166.19 KiB) Viewed 2030 times


Two new rods next to the old one.

Pushrods06.jpg
Pushrods06.jpg (216.97 KiB) Viewed 2030 times


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.

User avatar Great Britain
ianc53
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Posts: 610
Joined: Thu Feb 19, 2004 5:22 pm
Location: The Kingdom of Fife

Re: New pushrods

Postby ianc53 » Sun Feb 09, 2020 10:41 am

Well done, I'm always impressed when someone has the skills and equipment to solve problems like that!

Ian
Grey R1200RS SE 2016
Blue R100RS 1980
Suzuki GT250B 1977

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Phil K
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Joined: Tue Feb 13, 2007 9:26 am
Location: North Yorks

Re: New pushrods

Postby Phil K » Sun Feb 09, 2020 3:56 pm

Sweet
R11s + Val Singleton Power filter - Lennies induct - Y Piece - Wilbers - PC111
1974 Honda CB750 1974 Triumph Trident T150 Oh and a GS-LC

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nab 301
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Joined: Sat Dec 04, 2004 6:41 pm
Location: Dublin Ireland

Re: New pushrods

Postby nab 301 » Sun Feb 09, 2020 4:45 pm

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...
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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..

Pete.
Posts: 188
Joined: Thu Apr 02, 2015 7:16 pm

Re: New pushrods

Postby Pete. » Mon Feb 10, 2020 11:29 pm

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?

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nab 301
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Joined: Sat Dec 04, 2004 6:41 pm
Location: Dublin Ireland

Re: New pushrods

Postby nab 301 » Tue Feb 11, 2020 8:39 pm

Pete. wrote:.

The one-piece jobs must be all steel I guess?

Yup
Image
_________________
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..

Great Britain
boxerscott
Posts: 3485
Joined: Sat Apr 21, 2007 5:07 pm
Location: scottish borders
Contact:

Re: New pushrods

Postby boxerscott » Wed Feb 12, 2020 7:55 pm

Great post. Love these diy fixes.


Chris
You`ll never watch your life slide out of view? then drink and dance and .... :)


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