Wondering about valvecovers 99-03

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J

john_tonnesen

Joined
Apr 12, 2012
Messages
14
Location
Sweden
Hello.
I have been strugeling with a bad oilleak for some time. Finally found it, late last night. I have a crack in my valvecover, right through the cast numbers on top of the covers between the small valveadjustmentcovers.
I have a spare valvecover but it is in some way different. I think its from an 01. It doesnt have the left rockerarmbolts (the ones with nuts on the underside). This is the only differens i can find.

How will this affect the bike? I guess beacause mine is a 03 i have an uppdated v-cover so the bolts must be there for a reason.

Will my 03 rockerarms fit in this valvecover? It is an empty shell so i need to switch the rocks to the cover from 01.

Thanks for your help and greatings from a sunny Sweden /John
 
Hi

The cover is the same (01-03), you can change the rockers from one to the other.

:cheers:
ZAGA
 
Hi

If its 00 its other engine generation,

You can easely repair your valve cover with some metal liquid or devcon or something like that.
I have one spare cover that its repaired like that, and it wasen't a problem.

:cheers:
ZAGA
 
Check this pict

[attachment=0:2w77qtyi]Valv_cover_rep.jpg[/attachment:2w77qtyi]

:cheers:
 

Attachments

  • Valv_cover_rep.jpg
    Valv_cover_rep.jpg
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Ok, never seen that kind of alu-fix. Does that require to be melted on or what?? I have tried "tubemetall". Its a 2 compund metall that you mix and aply. Gets to hard for this application thou it cracks of vibrations and heat.

I can see that both of your covers on the pic misses the bolts i have on my broken one so i guess it will work. I will post a pick on my broken valvecover when i get time to change it.


Thanks for your time! //John
 
Its a cold process, and you don't have problems. At least I haven't.
I even done that with the DEVCON on a clutch cover.

There is a new type of glue that a salesman told me that its a wonder, when he show's me I let you know.

:cheers:
ZAGA
 
It doesnt fit!!!! I found stamps in both my cracked one and my spare one. The crack hade 03 stamped to it and the spare had 01 stamped.

Final conclusion. Rockers from 03 doesent fit into rockercover from 01. :spank:
see pic http://oi47.tinypic.com/10r1qfd.jpg

I will have to find a way to repair my old one.
The problem with cold solutions is that i think the crack comes from the pressurechannel that lubes the rockers. Not easy to fix pressure leakage. I will try to solder it with aluminum.
Any better ideas?

//John
 
Sorry didn't knew they were so different.

Knew the rocker were different, but as they used the same shafts, thought you would be ok.

Do you know exactly were that leak is ?

:cheers:
ZAGA
 
No problems, now we know.

I know where it is, its right through the pressure channel that feeds the rockers and up to the cast numbers on top of the valvecover.

So far...
I have tried to solder it with zincanode, aluminumsolder and tried some strange liquid metal. The metal i got a hold of was a 2 compound whit alupowder in one jar and some epoxy (i think) in another. Mixed it kind of thin the first try and tried to brush it on in layers.
Nothing seems to work. Two revs and the crack comes right through. The cover seem to be casted in a lowquality aluminium so tigwelding wont work. Just gets a big blue spark.
Have now mixed the liquide metal a little thicker and put it on. Well know in an hour if it worked. I hope for the best but my hopes is not high. :(

Maby stiching is my only option, Problem is that stichingkit is hard to get a hold of in sweden and even harder if its to aluminium. I know my dad have used it in the past to fix cracks in v8 cast iron heads.

Never heard of stitching?? Check this out: http://www.youtube.com/watch?v=2AqdyYvDZng


Anyone have a fresh 2003 valvecover for sale maby??
 
Yes it should be the same

But then again I also thought that the 01 was the same as the 03 :mrgreen:

Your byke is a 450 ?? The 450 only came in 04 :shock:

Is it possible that you have a 04 head ???? :shock:

:cheers:
ZAGA
 
Not a 450?? 8O Man, stopp messing with my head. The tag on the frame says:
92/61*0001*04
Yu7FE3E8530000007
Fe450

Motornumber stamped on the right side of cylinder
4543015

All decals says 450 but they are ratter easy to change i guess. Its roadlegal in sweden and my papers from the goverment says 2003 fe450.
So, what bike do i have? :shock:

I think i fixed the leake. Used multiple layers of liquid metal and i dont think its leaking anymore. Havent done any riding jet. Maby ill go out for a quick ride tomorrow before i go to denmark for American car meet. No moore stubborn bergs this weekend, just beer and american steel :cheers:

Thanks for all your help /John
 
My friend

The only thing that I can tell you is that there is no model 2003-450, you might have a early 2004-450, that was registed in 2003 ??

Until 2003 it was 400, but its simple, the 2003-400 had Dellorto carb and SEM ignition, then in 2004-450 it was FCR carb and kokusan ignition.

Its easy to check 8)

:cheers:
ZAGA
 
There were a very few 03 450 produced with Keihan carbs and SEM ign.
I was a dealer then and it was a special run the factory made for a few distributors for their sponsored riders.
the cylinder head combustion chambers were quite unlike anything in the regular production models.
The rod set was also not the same as the
04 -08 models and these parts for this special are difficult to find.
 
Thanks nsman, you are allways learnig :D

So john, just don't break anything on your engine, or you will be in troublle :mrgreen:

:cheers:
 

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