New pushrods

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Pete.
Posts: 238
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
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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
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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
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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
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Two new rods next to the old one.

Pushrods06.jpg
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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.

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ianc53
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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
Motorrad R1250RS SE 2023
Blue R100RS 1980
Suzuki GT250B 1977

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Phil K
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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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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: 238
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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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
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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..

boxerscott
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Location: scottish borders
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Re: New pushrods

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

Great post. Love these diy fixes.


Chris
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started out with nothing, still have most of it left.


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