Topic: Cant get valve cover back on

[juntjoo]

the right side sits over the head about a millimeter. towards the left it tapers down to make correct contact. All I did was unbolt it then lift it a bit out of the way(long story) then went to put it back and now this. It wasn't difficult to remove though. I took the speedometer or odometer or tachometer whichever it is, the gear, out in case the teeth weren't aligning. Nope. It feels like it's originating around the part where the cover and head fit together with the 7mm shaft that fits in the hole, like suddenly it won't fit but still I suspect there is something else going on like spring loaded previously til the moment I removed the cover. Any ideas?

[setdog]

maybe not lined up with the tach gear?  but you say you took it out?  maybe a dowel pin not seated all the way down?

[camshaft1991]

I had the same problem with my 350F. Try turning the crank over slightly and watch the cover settle or move. There’s s magic spot for the engine to be at for it to settle. Its not TDC, but it could be.


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[juntjoo]

I had the same problem with my 350F. Try turning the crank over slightly and watch the cover settle or move. There’s s magic spot for the engine to be at for it to settle. Its not TDC, but it could be.


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thanks. that's what I was thinking. will try in the morning

[Remcod]

Its the tappers. You have to release them enough from the valves. Otherwise you will strip the treads of the cover screws also for sure.

[DaveBarbier]

Yeah, lift the tappets off the valves or you'll bend a valve stem. Or, better yet, put rubber bands on the tappets to hold them up.

[juntjoo]

Its the tappers. You have to release them enough from the valves. Otherwise you will strip the treads of the cover screws also for sure.

thanks. could you elaborate a little? I'm not very familiar with cylinder heads. I replaced one in a 93 eclipse! but never worked on one.

[Remcod]

Sure. Take the round tappet adjustment caps of the valve cover. Release the nut from the tappet screw and screw this one up this making the distance between valve and tappet maximal. Do this for all 8.

Install the cover, do not use force on the screws, they are very delicate, you will strip the treads. I use my little finger so I cannot over tighten.

Then adjust all valves following the user manual.

[strynboen]

its a 650,,, so no raund..ones..

[Remcod]

Ah. I must be needing glasses, thought you were talking about a 350f that has the tappets installed in the cover. Sorry about that.

[strynboen]

no need for any sorry.

.the tread starter have not give any help.

.i just sav the 650 on the small reading in his avatar...

[juntjoo]

no need for any sorry.

.the tread starter have not give any help.

.i just sav the 650 on the small reading in his avatar...

i thought it was standard to identify someone's bike by what they have in their sig.

[FuZZie]

no need for any sorry.

.the tread starter have not give any help.

.i just sav the 650 on the small reading in his avatar...

i thought it was standard to identify someone's bike by what they have in their sig.

Too many guys in here have more that one bike... 

[juntjoo]

no need for any sorry.

.the tread starter have not give any help.

.i just sav the 650 on the small reading in his avatar...

i thought it was standard to identify someone's bike by what they have in their sig.

Too many guys in here have more that one bike... 

thanks. 82 nighthawk 650

this is as close as I can get turning the crankshaft. Any ideas? another tapper related solution?

[Bodi]

Since I see the rocker pivot shafts in the "cover", I believe the rockers are in there. I'm not familiar with this engine, it looks like you remove the breather and a couple of other top covers to adjust the valve clearances as it doesn't have the round tappet covers. But a tappet may be cocked beside a valvestem as can happen with the other under-750 fours?
If it's just the valvesprings pushing the cover up, you can force it down with the bolts - not one... work all the bolts around the cover a little at a time until it's down fully then go around and torque them - gently. The spec torque can be too much for the threads in the head, so be careful.
If a tappet screw end IS beside (not on top of) a valvestem DO NOT force it down, you will most likely bend the valve and be in serious trouble.

[camshaft1991]

I know my SOHC 350f bike is vastly different than your DOHC 650, but did you notice your cover move when you turned the crank? First off the valve tappet screws in the rocker arms should be backed out almost flush to where it barely sticks out at the bottom of each rocker arm. I think some others mentioned that too. Also the valve cap covers should be kept off.  If that gap in the picture you have right here changes as you turn the crank, then you’re getting somewhere. Remember, twice around with the crank is a full cycle. If it does not move when you rotate the crank then stop. If it does then use a feeler gauge when you notice the gap dissipate the least, or see if it still wobbles with the weight of your arm (not your whole body) on it.  Try to make a mental note or make a pencil mark on your spark advancer. My cover sat nearly perfect right before the 1&4 firing mark. Also when your cover rises drops, don’t turn the crank really fast or put weight on the cover. I chipped a  very small piece of mine because I put weight on it and turned the crank too fast. Luckily I found the little shard.


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[camshaft1991]

I couldn’t retrieve a video of the my cover rocking but this is my gap I struggled with

Also don’t rock it too much if it does. Someone told me not to do it too much or at all.. but I already made a video of it. And  I can’t seem to post it

[Scott S]

 Remove valve cover.
 Remove tappet covers.
 Loosen lock nuts on adjusters and back them out a good bit.
 Use rubber bands on each set of rockers to hold them up. #1 intake to #1 exhaust. The rubber band will lift up on the rockers. Repeat for other three. Have all four sets held up.
 Set #1 piston at TDC, just to ease in initial valve adjustment. Confirm that the notch on the end of the cam is correct.
 Install valve cover. You may have to tap *LIGHTLY* with a rubber hammer to seat it on the locating dowels.
 Install screws/bolts and torque correctly.
 Remove rubber bands.
 Tighten the adjusters by hand until they're loose on the cam lobes.
 Adjust first 4 rockers.
Rotate engine and adjust next 4.
 Rotate engine again and double check your work.

[camshaft1991]

Remove valve cover.
 Remove tappet covers.
 Loosen lock nuts on adjusters and back them out a good bit.
 Use rubber bands on each set of rockers to hold them up. #1 intake to #1 exhaust. The rubber band will lift up on the rockers. Repeat for other three. Have all four sets held up.
 Set #1 piston at TDC, just to ease in initial valve adjustment. Confirm that the notch on the end of the cam is correct.
 Install valve cover. You may have to tap *LIGHTLY* with a rubber hammer to seat it on the locating dowels.
 Install screws/bolts and torque correctly.
 Remove rubber bands.
 Tighten the adjusters by hand until they're loose on the cam lobes.
 Adjust first 4 rockers.
Rotate engine and adjust next 4.
 Rotate engine again and double check your work.

Scott, for a sec I was a bit dumbfounded at the what TEC was . I’m curious about the rubber band step. When you say lift up the rockers, do you mean lift up the rockers where they would make contact with the camshaft lobes, or lift up the side of the rockers with the valve tappets?
So tappets up rocker face down or
Tappets down rocker faces up?


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[DaveBarbier]

This should clarify things regarding the rubber bands.

[juntjoo]

I just read my manual on removing then reinstalling this part but never read anything about a "tappet". What is that?

Otherwise, looks like I have to loosen all(four) adjusting nuts then it will close, at leaat that is wbat the Clymer's guide explains. Then at that point I am supposed to adjust those nuts to adjust the valve clearances and apparently I'll need a special tool for that? I'll figure this out in the morning

[juntjoo]

Remove valve cover.
 Remove tappet covers.
 Loosen lock nuts on adjusters and back them out a good bit.
 Use rubber bands on each set of rockers to hold them up. #1 intake to #1 exhaust. The rubber band will lift up on the rockers. Repeat for other three. Have all four sets held up.
 Set #1 piston at TDC, just to ease in initial valve adjustment. Confirm that the notch on the end of the cam is correct.
 Install valve cover. You may have to tap *LIGHTLY* with a rubber hammer to seat it on the locating dowels.
 Install screws/bolts and torque correctly.
 Remove rubber bands.
 Tighten the adjusters by hand until they're loose on the cam lobes.
 Adjust first 4 rockers.
Rotate engine and adjust next 4.
 Rotate engine again and double check your work.

thanks. this is detailed and is close to my manual minus the rubber band thing. I'll get more into this in the morning. and what is this special tool only the manual is saying I need? ill find out in the morning what exactly I need...

[Scott S]

I just read my manual on removing then reinstalling this part but never read anything about a "tappet". What is that?

Otherwise, looks like I have to loosen all(four) adjusting nuts then it will close, at leaat that is wbat the Clymer's guide explains. Then at that point I am supposed to adjust those nuts to adjust the valve clearances and apparently I'll need a special tool for that? I'll figure this out in the morning

 The tappet is the rocker arm/adjuster set up.
 I would loosen ALL of them, not just four.
 I don't know what special tool you would need. There is a valve adjusting tool that makes it easier, but nothing you can't accomplish without a wrench and a screw driver.

[crazypj]

I just read my manual on removing then reinstalling this part but never read anything about a "tappet". What is that?

Otherwise, looks like I have to loosen all(four) adjusting nuts then it will close, at leaat that is wbat the Clymer's guide explains. Then at that point I am supposed to adjust those nuts to adjust the valve clearances and apparently I'll need a special tool for that? I'll figure this out in the morning

That comment immediately tells me you don't have a clue what your doing.
Sit down, slow down and do a LOT more reading
You've been given all the information you need in great detail.
You need to completely remove valve cover (after loosening ALL the locknuts) flip it over and unscrew ALL the adjusters until they are level with ends of rockers so rocker arm can easily 'slide' over valve tip. Use rubber bands as shown in picture wen re-assembling.
Trying to cut corners can easily 'destroy' cylinder head as well as crack area's of rocker cover.

[Remcod]

Does a nighthawk have hydraulic tappers?