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Old 12-11-2014, 10:11 AM   #1
FLypflap91 OP
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Cry XR/XL600 worn cam and rockers, PICS!

Hi

i thought my camchain/camchaintensioner is worn, so i removed my engine.

today i removed the valve cover and i think i found the problem that caused excessive engine noise, pic very related.

What can cause this, and what shold i do now?
i guess i'll need a new camshaft or have this one reworked, and new rockers?

what else should i check or renew?
the engine has ~30000 kilometers/18600 miles on it.


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Old 12-11-2014, 10:28 AM   #2
mcma111
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Running with low oil will do that. Have you done any maintenance to the bike lately?
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87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 12-11-2014, 11:18 AM   #3
FLypflap91 OP
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Bluhduh

Goddamnit.
are you sure this would cause only ONE cam to look that way?

no, i have not done any maintanance to the bike lately. i bought it a few months ago and when i testrode it, i already noted the clacking noises, thought its just wrong adjusted valves.

i check the oil quite regularly, but i suppese the pre owner didnt.

i guess i do have to have the cam reworked though, eh?
do you think this is what caused the noise?
here is a video of the bike running with the noise and stuff:

https://www.youtube.com/watch?v=APf6...ature=youtu.be

also, any tipps on removing the cam? i cant seem to open the two bolts that hold the camchainsprocket.
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Old 12-11-2014, 11:55 AM   #4
mcma111
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Yep, that's the noise.

What happens is the hardening on the rocker will fail and then it takes the cam lobe out.

On the stator cover, remove the bigger of the two caps and hold the bolt inside with a 17mm deep socket. It will want to rotate as you loosen the cam bolt. Be sure to use a box wrench on the cam bolt.
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BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 12-11-2014, 12:24 PM   #5
FLypflap91 OP
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Wicked

Thanks, that trick helped a lot, got it off.

now that i already have the engine removed, would you advise me to remove the cylinder and get a closer look to everything?

what i thought was

>remove head, check the sparkplughole for hairline fractures etc. (also the gasket leaks a bit so replacing that is needed)
>check the cylinder for wear
>maybe remove the cylinder too
>replace pistonrings?


so i think what i NEED to get for sure is:
>camshaft or have the old one reworked
>new rocker (is buying one sufficient or should i just get 4 new ones?)
>the gaskets of course
>maybe pistonrings?

and is there anything i should certainly NOT do?
something that i could not put back together myself if i take it apart, i do have basic tools but nothing special.
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Old 12-11-2014, 12:52 PM   #6
mcma111
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It all depends on how thick your wallet is. Over here the XL cams are no longer available and a reworked cam is very expensive. See what your options are.

if it was my engine I would send the head out to have a valve job done. Take the piston and cylinder to your machinist and have them measured to see if they are still in spec. If so have the cylinder honed and order a set of rings. If not then a first over piston set. Inspect the rockers and if a new or reworked cam is going to be used then buy a full set of rockers.

Some light reading:

http://advrider.com/forums/showthread.php?t=713831
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BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 12-11-2014, 01:03 PM   #7
FLypflap91 OP
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There is already a deep caving in the damaged rocker, i will certainly need a new one.

okay i'll just take the head off now and post pics when i did it.

do you know what a "valve job" costs, approx.?
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Old 12-11-2014, 01:15 PM   #8
gonerydin
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Running with insufficient, or no, clearance can cause excessive wear like you have there. That might explain why only one lobe is affected.
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Old 12-11-2014, 01:20 PM   #9
RFVC600R
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XR'S Only has a camshaft kit for the older bikes.

Crapatalk
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Old 12-11-2014, 01:22 PM   #10
mcma111
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Valve job is from $150.00 and up.
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BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 12-11-2014, 02:12 PM   #11
FLypflap91 OP
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There we go.

that doesnt look to bad, right? i mean, seems to me like for the most part, the engine is in fine condition.

what do you say?

there are small scratches on the front of the cylinder wall, but all in all not too bad?

should i open it up even MORE tomorrow?



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Old 12-11-2014, 02:27 PM   #12
mcma111
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Here is a test for you. Put the spark plug back in the head. Lay the head upside down on a level surface and pour some solvent in the combustion chamber. Wait a while and look for leakage out the intake and exhaust ports. Leakage = valves not fully seating/sealing.
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Steve in SF

BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 12-11-2014, 02:30 PM   #13
FLypflap91 OP
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Okay i'll do that tomorrow.

what kind of solvent should i use?
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Old 12-11-2014, 02:36 PM   #14
mcma111
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What do you have? Paint thinner, something light. Not gasoline.
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Steve in SF

BMW's
58 R26
79 R100s
91 R100gs

87 Harley FXRS-SP ~ 06 KTM 625 SMC ~ 72 Honda CB750/915cc ~ 92 XR600/654cc ~ 95 XR650l/675cc ~ 03 CRF450r ~ 05 CRF450x ~ 02 XR650l/675cc ~ 86 YZ490 ~ 93 YZ80 ~ 93 XR650l Project
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Old 12-11-2014, 02:38 PM   #15
FLypflap91 OP
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Paint thinner it is.
why not gas though?
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