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New pushrods

Posted: Sat Feb 08, 2020 11:15 pm
by Pete.
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

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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.

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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.

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Pushrods05.jpg
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Two new rods next to the old one.

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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.

Re: New pushrods

Posted: Sun Feb 09, 2020 10:41 am
by ianc53
Well done, I'm always impressed when someone has the skills and equipment to solve problems like that!

Ian

Re: New pushrods

Posted: Sun Feb 09, 2020 3:56 pm
by Phil K
Sweet

Re: New pushrods

Posted: Sun Feb 09, 2020 4:45 pm
by nab 301
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...

Re: New pushrods

Posted: Mon Feb 10, 2020 11:29 pm
by Pete.
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?

Re: New pushrods

Posted: Tue Feb 11, 2020 8:39 pm
by nab 301
Pete. wrote:.

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

Yup
Image

Re: New pushrods

Posted: Wed Feb 12, 2020 7:55 pm
by boxerscott
Great post. Love these diy fixes.


Chris