HELP! Cam/cam shaft gear bolts broke, what damage to engine

steepisgood · Jun 10, 2008

OK, 10 hours of street riding on the 05 fs 650c bike after a dealer in the northeast rebuilt my engine. I was riding on a highway 55mph and the bike shut off. No compression. After openning it up as per the dealer, I see the cam/cam gear bolts got loose and broke/ I checked the valves with a leakdown test and there is 100% leakdown in exhaust and intake valves. What other damage could be done to the bike? Is there any place to get valves cheaper. How would those bolts have gotten loose? Also, the two nuts in the crankcase(timing chain gear and gear below it) were loose, bottom one hand loose, other one not tight. no sign of locktight, is this normal?

please advise.

Taffy · Jun 11, 2008

RE: HELP! Cam/cam shaft gear bolts broke, what damage to eng

no it's not normal and it will be the dealers fault 100%.

i suggest that you take it back to him as is or do some yourself you pull the radiator and remove the cylinder head as well.

re-install the spark plug, lay the head face up and fill cylinder face with what you yanks call kerosene or white spirit. then check the the ports for wetness. this will tell you which ports have gone.

if you have a 35/30 head you can use turned down 37mm that went bad for someone. i have 4 here in the UK that i'll be using when machined. cost new in the UK is Ã‚Â£150 for 2 valves (thats $300 to you).

he should have loctited everything and perhaps like all humans he built it up intending to stick the air gun on the nuts when he had some resistance later in the rebuild.

then he forgot! i would insist on new woodruffe keys and i would look at the inside of the gears incase it was really rough and bashed about.

we're all human, as long as he comes clean and treats you right i'd let him do it. in the UK we have a different view to yanks on one or two things. here we ask nicely if they can repair it and we're terribly sorry to ask. in the USA i believe you chew their *****.

regards

Taffy

JoeUSA · Jun 11, 2008

Re: RE: HELP! Cam/cam shaft gear bolts broke, what damage to

Taffy said:
no it's not normal and it will be the dealers fault 100%.

i suggest that you take it back to him as is or do some yourself you pull the radiator and remove the cylinder head as well.

re-install the spark plug, lay the head face up and fill cylinder face with what you yanks call kerosene or white spirit. then check the the ports for wetness. this will tell you which ports have gone.

if you have a 35/30 head you can use turned down 37mm that went bad for someone. i have 4 here in the UK that i'll be using when machined. cost new in the UK is Ã‚Â£150 for 2 valves (thats $300 to you).

he should have loctited everything and perhaps like all humans he built it up intending to stick the air gun on the nuts when he had some resistance later in the rebuild.

then he forgot! i would insist on new woodruffe keys and i would look at the inside of the gears incase it was really rough and bashed about.

we're all human, as long as he comes clean and treats you right i'd let him do it. in the UK we have a different view to yanks on one or two things. here we ask nicely if they can repair it and we're terribly sorry to ask. in the USA i believe you chew their *****.

regards

Taffy

It could be worse that that Taffy.

When an intake valve spring broke on my 501, the valve, valve guide, and rocker arm bent when the broken spring got between the end of the valve and the swivel foot on the arm. The piston whacked the valve and that was it!

Joe

Taffy · Jun 11, 2008

RE: Re: RE: HELP! Cam/cam shaft gear bolts broke, what damag

cheers joe

when your luck is out hey!

listen steep, check that the nut on the end of the crank looks flush and flat ok? if the nut has a circular recess in the front face it means it was put on the wrong way round.

to understand, undo the nut you have and look at both sides. you'll see the recess. thie recess should face the gear and be UNSEEN.

regards

Taffy

steepisgood · Jun 12, 2008

RE: Re: RE: HELP! Cam/cam shaft gear bolts broke, what damag

Thanks Taffy,

I will check tonight but I recall it appearing recessed on the outside, not towards the gear. by the way I am looking to download anything in regards to torque specs and rebuild but couldn't find it at "downloads".
Dealer said I must have beat the crap out of the bike for the two cam nuts to get loose. He didn't want to hear that I had 10 average street hours on the bike. Not sure what he is going to do. He is 4 1/2 hours away driving each way, and he wants me to bring the bike back to him so he can check it out, no promises. I'm not sure if I want them working on it again anyway. So you may have valves for sale?

thanks,
Edwin

spanner · Jun 13, 2008

RE: Re: RE: HELP! Cam/cam shaft gear bolts broke, what damag

Whats his name /business ?.
The internet is a powerful tool!
Cheers Spanner.

JoeUSA · Jun 13, 2008

Re: RE: Re: RE: HELP! Cam/cam shaft gear bolts broke, what d

steepisgood said:
Thanks Taffy,

I will check tonight but I recall it appearing recessed on the outside, not towards the gear. by the way I am looking to download anything in regards to torque specs and rebuild but couldn't find it at "downloads".
Dealer said I must have beat the crap out of the bike for the two cam nuts to get loose. He didn't want to hear that I had 10 average street hours on the bike. Not sure what he is going to do. He is 4 1/2 hours away driving each way, and he wants me to bring the bike back to him so he can check it out, no promises. I'm not sure if I want them working on it again anyway. So you may have valves for sale?

thanks,
Edwin

Popycock!

IMHO whoever worked on your bike must have forgotten to use RED loctite on those bolts and torque them properly. He did not follow the factory service manual!

Regards,

Joe

steepisgood · Jun 14, 2008

RE: Re: RE: Re: RE: HELP! Cam/cam shaft gear bolts broke, wh

No loctite on any of the two bolts or the nuts. Spoke to the dealer and told him I would have my local mechanic repair the bike, I w5ould take care 5of the labor, and mail him 5the damaged parts t5o be replaced.
He should be taking care of that stuff.

Edwin
555

HELP! Cam/cam shaft gear bolts broke, what damage to engine

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