Broken tappet

[bomber]

Hello,
After successful rebuild of carbs, thanks to this forum (and usa one too), I finally started to sort my bike properly, thought first check and adjust tappets, and while un screwing locknut I managed to brake tappet.
Now, to fix that I have to drill a hole and unscrew remaining bit, my problem is that it seems impossible to drill a straight hole on a angle...
Another thing is after close inspection of a tappet it surface seems very uneven, is this "normal", should I replace them all?
Any advice much appreciated.


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[hairygit]

DON'T whatever you do risk drilling it, you will always end up with some swarf loose in the engine, it's really not worth the risk. Take the rocker cover off and do it from underneath, it's very easy on a 500/550 four, on a standard 750 the engine has to come out! So get a rocker gasket and the tappet you need, couple of hours tops even if you've never done it before

[bomber]

Picture showing tappet as described earlier

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[mickwinf]

Hairygit beat me to it, take the rocker cover off!

[bomber]

Thanks!
Sounds much easier then drilling 
It will also give me a better idea what kind of mess is there.
Think will need to buy tourque wrench 
In manual it said to slackened off all tappets, why would it be necessary?

DON'T whatever you do risk drilling it, you will always end up with some swarf loose in the engine, it's really not worth the risk. Take the rocker cover off and do it from underneath, it's very easy on a 500/550 four, on a standard 750 the engine has to come out! So get a rocker gasket and the tappet you need, couple of hours tops even if you've never done it before

[hairygit]

Because the rocker shafts which the rockers ride on are fitted into the cover. When you remove the cover all the rockers come off with it, slacking the tappets reduces the  upward pressure on the cover making it easier to refit, the broken one will not cause any problems removing the cover

[Trigger]

Slacken off all the tappets so they are not compressing the valves. Not sure where you live, but if it's anywere near me i have a nice 3/4 drive britool torque bar that does the job. Try not to be so heavy handed.

[hairygit]

i have a nice 3/4 drive britool torque bar that does the job. Try not to be so heavy handed.

  3/4 drive, that's HGV stuff, and you say don't be heavy handed lol

[Trigger]

It was a joke mate. That's why i wrote, not to be so heavy handed. A 3/8 drive torque bar is needed.

[LesterPiglet]

And before reassembly please read about the correct method using elastic bands...no joke.

[bomber]

I'm on North London, think it is time to buy torque wrench, not sure what size and make... just had a look at Machine Mart website and think this looks like a possibility http://www.machinemart.co.uk/shop/product/details/cht141-1-2in-drive-torque-wrench

Slacken off all the tappets so they are not compressing the valves. Not sure where you live, but if it's anywere near me i have a nice 3/4 drive britool torque bar that does the job. Try not to be so heavy handed.

[Trigger]

The torque bar your looking at are not very good, your need a smaller one for tappet nuts. I always use Britool torque bars, but are for professional use. Lester is spot on about the elastic bands, hes not joking this time.
Your not too far away from me.

[mickwinf]

A 3/8 torque wrench is a better bet for our bikes as a lot of the specs are below the range of the bigger ones, mostly under 20 lbs ft. I have a draper one which was not too expensive.

[Trigger]

Mike, I did send bomber a PM explaining everything he was getting in a bit of a mess. bomber, once you get your rocker off, check all your tappets for any chips. If you find any that are chipped, check all the valves for any damage.

[bomber]

Just lost the Brittool 3/8 on fleabuy bummer 

I have to make a list of the sockets and spanners and buy good quality ones... don't want to round off any bolts, and torque wrench is high on the list!

Thanks so much for advice so far, would love to get bike back on the road asap.