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August 10th, 2016, 05:58 AM   #1
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I Ride: '04 FE 400
'03 FE400 snapped tappets

Hi all,

was out on the bike on Sunday and noticed an intermittent "chinking" noise. After a few hours riding it bogged down on me and eventually cut out and refused to start.

Pulled the plug out and it was soaked so stripped and cleaned the carb to start with, no joy.

Gave Taffmeister a call and he recommended pulling the rocker cover to have a look. Low and behold, there it was.

I've snapped both inlet tappets and the inlet rocker arm is stiff (collapsed bearing?). Also noticed the inlet rocker appears to be missing a bearing... Cant' visibly see any shrapnel which is worrying, may not have even been there in the first place.

Are these prone to snapping tappets?

Cheers

***EDIT***
Upon further inspection, I have found what appears to be the missing bearing. Unfortunately I've only managed to recover around an 1/8th of the outer casing. What would be the best option from here, i.e. flush the engine out or strip and rebuild?

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Last edited by JesseDT; August 10th, 2016 at 06:37 AM.
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August 10th, 2016, 09:54 AM   #2
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I Ride: 04 FE650E
considering the length of time it ran after starting to destroy the bearing, you should have shrapnel everywhere. also look over the bearings on the ends of the cam, it looks like you had a race spinning.
the proper way is to do a teardown.
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August 10th, 2016, 10:32 AM   #3
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the tappets must have been so loud Jesse....you have to be stone mutton!!!! (Mutt 'n Jeff = Stone deaf! cockney rhyming slang!)

the tappets will probably have had so much space that there was percussion.

check the cam lobes, use only sealed cam bearings (6201s), don't bother with the '01' cam fropm the 400 anyway, get the 53 cam and re-jet. go to DVSK. check the valve stems for flatness on the ends. the 400 inlets always tulip.

do the job properly - you'll be rewarded.

regards

Taffy

Last edited by Taffy; August 12th, 2016 at 01:37 AM.
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August 10th, 2016, 01:50 PM   #4
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I Ride: '04 FE 400
I did think it was rather rattly but it was my second time riding it, still getting used to the noises and thought I was being OTT paranoid... oops!

Cam lobes look OK, slight wear on the nose of them but if I was to have it rebuilt it may as well be upgraded.

Taff I'll give you a bell tomorrow about getting the lump up to you for you to do your magic, I'm off to look for pennies under the sofa!

Cheers for the replies guys

Jesse
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August 11th, 2016, 12:36 AM   #5
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where in Surrey are you?

might be down your way this weekend?

Taffy
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August 11th, 2016, 02:29 AM   #6
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I'm in Chessington, not too far from the zoo.

If you're in the area feel free to drop in for a cuppa!
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