Too much radial play in rocker arm

Teodor1 said:

Today I ordered a complete new intake rocker arm setup including the bushings,bearing,adjusting screws and lock nut. That should do the trick.

Did not think that it would be so expensive, how much does a rocker arm cost aproximately? I'm getting worried when you say things like that :shock:

The cam bearings will have to wait for about a week but I'am not so worried they should last that long atleast.

I am sure that I adjusted the valves at the compression stroke it's just that I ran onto some bad luck whit the nut coming loose. And from now on I wont touch the feeler gauge and just use the 1/6th method.

torque wrench whats that :wink: I go on feeling when I tighten the locknuts but maybe I should order a wrench too hah

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I don't know where you live, but the rocker arm can cost from about $100-$200 US each

A torque wrench is available at just about every Tool shop or Auto parts store.

It is a tool that you use to tighten a bolt or nut etc. It has a scale on it that measures how hard you are tightening the bolt or nut so you can put the exact same torque on it as Husaberg says too in the service manual. If you do not torque (tighten) the screw hard enouch it can loosen when the motor is running , very bad. If you torque it too hard, you can strip the threads in the bolt or nut or rocker arm or even crack the bolt or valve adjusting screw such that it will break while the engine is running.

You want one that is 1/4" or 3/8" drive. The beam type are much less expensive but work great. With the beam type you have an indicator that you watch as you tighten that works just like a speedometer. The much more expensive type is called a preset click type which you set a dial to the value you want and then when you start tightening the bolt the wrench clicks in your hand when you get to the value you set.
Here is an example from Sears And Roebuck

http://www.sears.com/sr/javasr/search.d ... tical=TOOL

I paid $24 US for my 3/8" beam torque wrench.

You will nead a set of metric sockets to use with it.

You always want to use 6 point sockets, never 12 point because the 12 point are more likely to strip the head of the bolts or nuts.

Regards,

Joe

Ouch I hope the rockerarms are abit cheaper here in Sweden than in the US, and yes thanks I know what an torque wrench is I was ironic ;p Thanks for the reply though.

Anyone knows the difference between a 2002 and a 2003 rockerarm? I have a 2002 Fe650 but I ordered a 2003 rockerarm since the guy before me told me that he had exchanged all the parts in the top end to 2003 modell.

If it aint upgraded already do the head need much modifying to fit the 2003 rockers?

Teodor1 said:

Ouch I hope the rockerarms are abit cheaper here in Sweden than in the US, and yes thanks I know what an torque wrench is I was ironic ;p Thanks for the reply though.

Anyone knows the difference between a 2002 and a 2003 rockerarm? I have a 2002 Fe650 but I ordered a 2003 rockerarm since the guy before me told me that he had exchanged all the parts in the top end to 2003 modell.

If it aint upgraded already do the head need much modifying to fit the 2003 rockers?

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They look almost the same as the 02 arms. The 03 cam follower bearing has a smaller diameter axle and larger diameter needle bearings. It lasts about 50% longer than the 01-02 cam follower bearing. No modifications are required to the head or any other part of your bike to use the 03 arms..

Sorry, the 03 cam follower bearing will not fit into the 89-02 rocker arms so none of the early arms can be upgraded, they have to be replaced..

But, I am concerned, because you named your post thread" too much radial play in rocker arm"

If your head cover did not have the little item # 22 oil ring around the oil hole in the top of the head when you had the head cover off or if the hole in the head or head cover is plugged with silicone then your rocker arms may not be getting oiled properly. look at the attachment in this post.

Its rare that the rocker arm shafts need to be replaced before 400 hours.

01,02 & 03 were the only years that has pressurized oil to the rocker arms, all other years had splash oil holes in the rocker arms like the picture in my gallery

Regards,

Joe

JoeUSA said:

No modifications are required to the head or any other part of your bike to use the 03 arms..

Sorry, the 03 cam follower bearing will not fit into the 89-02 rocker arms so none of the early arms can be upgraded, they have to be replaced..

But, I am concerned, because you named your post thread" too much radial play in rocker arm"

If your head cover did not have the little item # 22 oil ring around the oil hole in the top of the head when you had the head cover off or if the hole in the head or head cover is plugged with silicone then your rocker arms may not be getting oiled properly. look at the attachment in this post.

Click to expand...

I found the little #22 oil ring you mentioned, although I am not completely certain that the oil ring was placed at the right hole in the head. It was placed at the hole in the head that is closest to the #13 bolt for cylinder head.

Also when I removed the bolts that locks the rockerarms axial play the threads in them were full of stiffened glue of some sort,just like silicone. The lubing system dont go trough there somewere does it?

I cannot in my brightest mind figure out how I would clean the oil chanels for the lubing system. The only chance would be to blow with air but silicone doesn't come loose that easily if it's stuck in such a small space!

I am just like you a bit puzzeled over the fact that the axial play had gone loose so quickly over an hour but when I adjusted it the problem was solved.

Atleast until the lock nut came loose on the valve adjustment screw and the valve clearance became huge again, but the axial play was still fine after the adjustment I made.

Teodor1 said:

JoeUSA said:

No modifications are required to the head or any other part of your bike to use the 03 arms..

Sorry, the 03 cam follower bearing will not fit into the 89-02 rocker arms so none of the early arms can be upgraded, they have to be replaced..

But, I am concerned, because you named your post thread" too much radial play in rocker arm"

If your head cover did not have the little item # 22 oil ring around the oil hole in the top of the head when you had the head cover off or if the hole in the head or head cover is plugged with silicone then your rocker arms may not be getting oiled properly. look at the attachment in this post.

Click to expand...

I found the little #22 oil ring you mentioned, although I am not completely certain that the oil ring was placed at the right hole in the head. It was placed at the hole in the head that is closest to the #13 bolt for cylinder head.

Also when I removed the bolts that locks the rockerarms axial play the threads in them were full of stiffened glue of some sort,just like silicone. The lubing system dont go trough there somewere does it?

I cannot in my brightest mind figure out how I would clean the oil chanels for the lubing system. The only chance would be to blow with air but silicone doesn't come loose that easily if it's stuck in such a small space!

I am just like you a bit puzzeled over the fact that the axial play had gone loose so quickly over an hour but when I adjusted it the problem was solved.

Atleast until the lock nut came loose on the valve adjustment screw and the valve clearance became huge again, but the axial play was still fine after the adjustment I made.

Click to expand...

O.K. but you did indicate the rocker arm had a lot of radial play. Did you mean axial play???? Or did you mean the valve adjustment was real loose because the lock nut came off ov the valve adjusting screw?

Why do you want to replace the rocker arm if the valveadjusting screw threads in it are not stripped and they are still snug on the rocker arm shafts?

The material used to seal the head cover (cam cover) to the top of the head is silicone. The scrdws that lock down the axial play of the rocker arms also hold the head cover onto the head and will get silicone on them during assembly of the head cover to the head.

Figute out which hole in the head cover lines up with the oil hole (with the o-ring) in the head and blow compressed air into it. YUou should see oil and air bubble out of the tiny squirt holes in the rocker arms. If you have the rocker arms and rocker arm shafts out of the head cover, you should be able to see oil and air shoot out of the cover counter bores whetre the inside ends of the rocker arm shafts fit. If you do then the oil passage in the head cover is not plugged.

Lots of questions,

Regards,

Joe

JoeUSA said:

If you push too hard on the end plug you just reach in and pull the rocker arm back on the shaft, this will move the end cap back and you can then start over.

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Well, I tried pulling it back and it's not going to budge... Any other ideas?

JoeUSA said:

O.K. but you did indicate the rocker arm had a lot of radial play. Did you mean axialplay???? Or did you mean the valve adjustment was real loose because the lock nut came off ov the valve adjusting screw?

Click to expand...

Sorry I did mean axial play, although it had alot of play because the lock nut came of too as you pointed to.

Today I removed the camshaft and the bearings one of the bearings were shot and the camshaft itself had became blue because of the heat on some places that I didn't see earlier.

So tomorrow I am going to order a new camshaft and some other stuff to..

I'm changing the rocker arm just to get the bigger cam follower bearing. I found out that it wasn't upgraded to 2003 model. At this point, I am beginning to doubt that the engine has 30hours on it since complete overhaul. But of course the lock nut thing was my own fault.

Anyone knows aprox how much a camshaft would cost? Is the lineweaver camshafts still available?

Note to self: always do things correctly and don't do it too hastily or you will pay for it :roll: