Topic: 1976 CB550 Cylinder Head Cover not seating properly

[Nick P]

Hello everyone!  First off, thank you so much for the advice and knowledge that everyone here has shared.  I've never really worked on motors before, but because of this forum, and all of you, I've gained the confidence and learned some super valuable skills!  Anyway, here's the deal...

I had a head gasket leak, so I decided to replace the gasket myself.  I left the motor in the frame and was relatively easily able to break the engine down, removing everything up to and including the cylinder block.  I gave the pistons and engine a nice cleaning, replaced a bunch of gaskets, and put it back together.  I made sure that I lined up the notch on the cam shaft on the (rider's) right side with the surface of the cylinder head and made sure the "T 1-4" timing mark was aligned with the index mark. 

Now here's the trouble - when I attempt to put the cylinder cover back on, the rocker arm and tappet adjuster are both coming into contact with the camshaft and valve end, thus preventing the cylinder cover from properly seating on top of the cylinder head.  Rotating the cam shaft only moves which rocker arms prevent a proper seat, so it seems across the board.  I've done the trick with the rubber bands to hold the tappet adjusters up.  I was going to check and adjust the valve timing anyway, but I haven't adjusted any of the tappets before, so I'm not sure why it won't seat normally as it had before.  Is this normal when reassembling the engine, or am I missing something?  I just want to make sure I'm not doing something stupid, and will not damage the engine when I try to start it up again. 

Thank you again to everyone who helps out on this forum... I would never had made it this far without it!

[flatlander]

back off the tappet adjust screws completely.
there will then still be a little bit of spring pressure. make sure you tighten the bolts in a pattern similar to that of the nuts holding the cylinder on the studs (see honda shop manual - you have one?), and tighten them down in turns, a bit at a time to build up pressure evenly.

[strynboen]

yes it vill not fall free dovn and click inn..another thing is the cam thain tensioner..thek in the sump..that the tensioner  fits the groove..the one in Photo is jumped aut and hits the start makanism clutch

[BomberMann650]

Rubber bands and no adjustment screws usually lets the rockerbox seat.  Watch for the dowelpins.  Those have to line up too.

[Nick P]

Thanks so much for the replies!  The Cam Chain Tensioner is good.  Just so I'm clear, I'll perform the following steps:

1. Loosen all tappet adjuster screws all the way out
2. Seat the cylinder head cover making sure dowel pins are lined up
3. Torque it down gradually and evenly
4. Adjust tappet screws by performing Valve Adjustment according to my Clymer Manual

This was going to be my course of action, but I'm glad that you guys confirmed it.  I just wanted to make sure that this was normal when taking apart the engine (even though I never touched the tappet screws), and that I didn't do anything lower down in the engine that could possibly cause this symptom.  Thanks again!

[BomberMann650]

should be able to press down with your hands before installing hardware.

[DaveBarbier]

You installing new rubber pucks that go over the head bolts? Your existing ones are probably squished too thin to seal. They don't normally come in gasket kits.


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[Nick P]

I should be able to press down with your hands before installing hardware.

Bomber - Right!  I'm not able to push the cover all the way down without the bolts in (and I haven't attempted to put the bolts in because it didn't seem right). 

You installing new rubber pucks that go over the head bolts? Your existing ones are probably squished too thin to seal. They don't normally come in gasket kits.

Dave - Are you referring to the 12 head nuts that all need to be torqued in a specific order (see pic)?  If so, when I took them off, there were no rubber pucks on them; just washers. 

[BomberMann650]

Sure you’re not putting the head cover on backwards?   

The rubber pucks go into the half a dozen open holes in the head.  Stopping the oil from getting out and making a mess.

[Nick P]

Sure you’re not putting the head cover on backwards?   

The rubber pucks go into the half a dozen open holes in the head.  Stopping the oil from getting out and making a mess.

Yes, I'm positive!  Haha!  There's only one way to put it on anyway.  And now I know what you mean by the rubber pucks!

[OldSchool_IsCool]

Be sure to tie back the tapperts!  Loop a rubber band over the exhaust tappet then out the inspection hole.  Loop the other end over the intake tapped through it's inspection hole.  Do this for all 4 cylinders. 

[DaveBarbier]

Be sure to tie back the tapperts!  Loop a rubber band over the exhaust tappet then out the inspection hole.  Loop the other end over the intake tapped through it's inspection hole.  Do this for all 4 cylinders.

I've done the trick with the rubber bands to hold the tappet adjusters up.

[RAFster122s]

Are you certain you are not running into an issue with the dowel pins between the cover and the cylinder head?  Sounds like the most likely cause, their tolerance requires them to be nearly perfectly aligned.
If you pull the dowel pins can you seat the cover then?

[jonda500]

Now here's the trouble - when I attempt to put the cylinder cover back on, the rocker arm and tappet adjuster are both coming into contact with the camshaft and valve end, thus preventing the cylinder cover from properly seating on top of the cylinder head.  Rotating the cam shaft only moves which rocker arms prevent a proper seat, so it seems across the board.

Perfectly normal - even after backing off all the adjusters. You can very loosely screw down the side that's not being held up, then turn the engine till the other side comes down flush.
John

[Nick P]

Thank you everyone for your input and help!  I ended up completely loosening all the tappets and then re-doing the timing.  I'm very happy to say that my first engine rehab was a success and she started right up sounding good!  Thanks so much!