Big Evo issue
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3rd Gear
Joined: Aug 2016
Posts: 7
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From: Boston
Big Evo issue
Here goes it...
- Bike **** the bed on me and after getting it home, I noticed the rear cylinder exhaust pushrod was bent to hell. Couldn't even get it started.
- I have a brand new lower end that was sent to me from Midwest because I had an oil leak from day 1 but didn't feel like pulling the motor at the time. That time has come!
- Got the Ultima 127 out of the bike and started to break it down. Here are the results so far of what I have done
One of the front or rear lifters in the tappet
Another view of the lifters chewed to hell
Here is the bent pushrod (Believe it or not with all 4 lifters torn up, only 1 pushrod was bent)
First shot of the cam (which is also very hard to turn while attached to the nose cone)
2nd shot of the cam
Now this is where all the metal shavings were found! They ONLY seemed to be in the lower left part behind the nose cone
This is where the breather gear goes. Is the rear of that seat supposed to look like that?
With all this said, What the hell went wrong? I'll be breaking the rest of it down soon to inspect the valves, cylinders, pistons, everything else pretty much.
Also, I'm lost when it comes to the "lift", "duration", etc. I just need an an answer on that cam and lifters I should be looking at (spec wise)
I appreciate the help in advance!!
- Bike **** the bed on me and after getting it home, I noticed the rear cylinder exhaust pushrod was bent to hell. Couldn't even get it started.
- I have a brand new lower end that was sent to me from Midwest because I had an oil leak from day 1 but didn't feel like pulling the motor at the time. That time has come!
- Got the Ultima 127 out of the bike and started to break it down. Here are the results so far of what I have done
One of the front or rear lifters in the tappet
Another view of the lifters chewed to hell
Here is the bent pushrod (Believe it or not with all 4 lifters torn up, only 1 pushrod was bent)
First shot of the cam (which is also very hard to turn while attached to the nose cone)
2nd shot of the cam
Now this is where all the metal shavings were found! They ONLY seemed to be in the lower left part behind the nose cone
This is where the breather gear goes. Is the rear of that seat supposed to look like that?
With all this said, What the hell went wrong? I'll be breaking the rest of it down soon to inspect the valves, cylinders, pistons, everything else pretty much.
Also, I'm lost when it comes to the "lift", "duration", etc. I just need an an answer on that cam and lifters I should be looking at (spec wise)
I appreciate the help in advance!!
Seasoned HDF Member
Joined: Dec 2009
Posts: 9,156
Likes: 1,904
From: Doghouse... mostly
I've got no words for what I'm looking at. Certainly did a number on the lower end. I suggest you go out and purchase an economy size bottle of aspirin cause you're gonna need it!
Thread Starter
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3rd Gear
Joined: Aug 2016
Posts: 7
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From: Boston
WONDERFUL! I already have a brand new lower case so Im not worried about that. I'm going to have to buy pushrods, lifters, a cam, and hopefully thats it besides gaskets/seals. I hope there is no cylinder/piston or valve damage. OOOFFFFF
Seasoned HDF Member
Joined: Dec 2009
Posts: 9,156
Likes: 1,904
From: Doghouse... mostly
You may luck out with just a hone job for the cylinder walls along with a new set of rings and valve guides. Everything that you listed can be had at a reasonable price so it shouldn't whack your bank account too badly.
Seasoned HDF Member
Joined: Mar 2010
Posts: 21,019
Likes: 7,547
From: Poolville
Usually a bent pushrod would indicate valve to piston interference.... Not sure that motor would be worth rebuilding. For $4800 you can just replace.
Definitely looks like lack of oil......
Definitely looks like lack of oil......
Thread Starter
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3rd Gear
Joined: Aug 2016
Posts: 7
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From: Boston
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Road Warrior
Joined: Aug 2007
Posts: 1,560
Likes: 66
From: Oakdale Ca.
I had the same exact failure on my 127 in 2007. It was not a valve clearance issue. It was shitty rocker arms that eventually snapped taking out my rocker box. So even though Ultima sent me out cam lifters rocker arms and valve covers ( out of warranty). So I promptly sold the new Ultima parts on ebay. I replaced them with Jims rocker arms lifter blocks and tappets. I used fuel motor style pushrods. And installed a s&s 640 cam. Ran better and much quieter.
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One needs to stay on top of the lifter roller fitment in an Evo, as there was a service bulletin issued to the dealers back in the day to "inspect and/or replace" at 25,000 miles.......more so even with a high lift/aggressive ramp cam profile.
Hardened bearing roller/cam lobe debris has now gone through that entire engine/oil lines/oil bag.
Complete and total tear-down/inspection if it were here.
Scott
Hardened bearing roller/cam lobe debris has now gone through that entire engine/oil lines/oil bag.
Complete and total tear-down/inspection if it were here.
Scott
