Valve rocker arm replacement

swede core · April 2nd, 2013, 11:24 PM

I was doing a valve adjustment and tightening the locknut on an intake valve rocker arm, and it flew out of its socket and chipped

. It is a ball and socket joint

and I have a seized ninja 250 engine as well as a older engine I received. I can take the rocker arm from the seized engine, if it is removable.

How would I perform the replacement? What do I need to remove and get to and if there is any know instructionals on this that would be great!

n4mwd · April 3rd, 2013, 05:16 AM

Good thing you caught it before you put it back together. Overtorquing the rocker arms during a valve adjustment will destroy the engine if you run it like that. The max torque on the nuts is about 15#.

But to answer the question, you have to remove the cams - actually, just loosen them - to get to the rockers. So basically:

1) removed the cam chain tensioner,
2) remove the cam caps - leaving the sprocket still connected.
3) reach in and remove and replace the rocker.
4) put the cam caps back on.
5) Verify cam timing (it can slip a tooth while you are working on it) and then fix the cam timing according to the manual.
6) Verify the cam chain tensioner lever isn't stuck and work it free.
7) oil and reinstall the cam chain tensioner.

That should do it for you.

n4mwd · April 3rd, 2013, 05:19 AM

Oh, and one other thing. You need to inspect ALL of your rockers to make sure they aren't also broken. If any have broken dog ears, then they will work out and destroy the engine.

Doesn't look that threatening, but it is.

n4mwd · April 3rd, 2013, 05:22 AM

Oh, and invest in a $10 torque wrench at harbor freight. Otherwise, you'll be stripping the cam caps as well.

Motofool · April 3rd, 2013, 05:58 AM

Welcome to the site, Kyle !!!

swede core · April 3rd, 2013, 07:31 AM

Yea I need to go an get a torque wrench :/

Whats the trick to removing and reinserting the rocker arms? Do you just pull them off and push them back in?

Thanks a lot for the feedback!

n4mwd · April 3rd, 2013, 07:38 AM

Quote:

Originally Posted by swede core

Yea I need to go an get a torque wrench :/

Whats the trick to removing and reinserting the rocker arms? Do you just pull them off and push them back in?

Thanks a lot for the feedback!

pretty much. You just have to make sure they're sitting in there socket properly. Other than that it's the cams that actually hold them in.

swede core · April 3rd, 2013, 07:39 PM

Any idea the torque spec on the cam caps?

Despite all of the headaches i've encounter with this engine swap/rebuild... I'm having fun! I sure wanna hop back on the bike soon though.

n4mwd · April 3rd, 2013, 08:23 PM

Rocker arm nuts = 12#
Cam caps = 9#

They are very easy to strip.

April 2nd, 2013, 11:24 PM	#1
swede core ninjette.org member Name: Kyle Location: Bay Area Join Date: Mar 2013 Motorcycle(s): Ninja 250 Posts: 11	Valve rocker arm replacement I was doing a valve adjustment and tightening the locknut on an intake valve rocker arm, and it flew out of its socket and chipped . It is a ball and socket joint and I have a seized ninja 250 engine as well as a older engine I received. I can take the rocker arm from the seized engine, if it is removable. How would I perform the replacement? What do I need to remove and get to and if there is any know instructionals on this that would be great!

April 3rd, 2013, 05:16 AM	#2
n4mwd ninjette.org certified postwhore Name: D Location: Palm Beach, FL Join Date: Oct 2010 Motorcycle(s): 2006 Ninja 250R, 2007 EFI Ninja 250R Posts: A lot. Blog Entries: 1	Good thing you caught it before you put it back together. Overtorquing the rocker arms during a valve adjustment will destroy the engine if you run it like that. The max torque on the nuts is about 15#. But to answer the question, you have to remove the cams - actually, just loosen them - to get to the rockers. So basically: 1) removed the cam chain tensioner, 2) remove the cam caps - leaving the sprocket still connected. 3) reach in and remove and replace the rocker. 4) put the cam caps back on. 5) Verify cam timing (it can slip a tooth while you are working on it) and then fix the cam timing according to the manual. 6) Verify the cam chain tensioner lever isn't stuck and work it free. 7) oil and reinstall the cam chain tensioner. That should do it for you. __________________________________________________ My Ninja Blog Proud member of ABATE.My NYC Road Rage documentary - CENSORED!
	1 out of 1 members found this post helpful.

April 3rd, 2013, 05:19 AM	#3
n4mwd ninjette.org certified postwhore Name: D Location: Palm Beach, FL Join Date: Oct 2010 Motorcycle(s): 2006 Ninja 250R, 2007 EFI Ninja 250R Posts: A lot. Blog Entries: 1	Oh, and one other thing. You need to inspect ALL of your rockers to make sure they aren't also broken. If any have broken dog ears, then they will work out and destroy the engine. Doesn't look that threatening, but it is. __________________________________________________ My Ninja Blog Proud member of ABATE.My NYC Road Rage documentary - CENSORED!
	1 out of 1 members found this post helpful.

April 3rd, 2013, 05:22 AM	#4
n4mwd ninjette.org certified postwhore Name: D Location: Palm Beach, FL Join Date: Oct 2010 Motorcycle(s): 2006 Ninja 250R, 2007 EFI Ninja 250R Posts: A lot. Blog Entries: 1	Oh, and invest in a $10 torque wrench at harbor freight. Otherwise, you'll be stripping the cam caps as well. __________________________________________________ My Ninja Blog Proud member of ABATE.My NYC Road Rage documentary - CENSORED!
	1 out of 1 members found this post helpful.

April 3rd, 2013, 05:58 AM	#5
Motofool Daily Ninjette rider Name: Hernan Location: Florida Join Date: Mar 2011 Motorcycle(s): 2007 Ninja 250 Posts: A lot. MOTY - 2016, MOTM - Dec '12, Jan '14, Jan '15, May '16	Welcome to the site, Kyle !!! __________________________________________________ *Motofool* *.................................Never ride faster than your guardian angel can fly* "Mankind is composed of two sorts of men — those who love and create, and those who hate and destroy. Love is the bond between men, the way to teach and the center of the world." - José Martí

April 3rd, 2013, 07:31 AM	#6
swede core ninjette.org member Name: Kyle Location: Bay Area Join Date: Mar 2013 Motorcycle(s): Ninja 250 Posts: 11	Yea I need to go an get a torque wrench :/ Whats the trick to removing and reinserting the rocker arms? Do you just pull them off and push them back in? Thanks a lot for the feedback!

April 3rd, 2013, 07:39 PM	#8
swede core ninjette.org member Name: Kyle Location: Bay Area Join Date: Mar 2013 Motorcycle(s): Ninja 250 Posts: 11	Any idea the torque spec on the cam caps? Despite all of the headaches i've encounter with this engine swap/rebuild... I'm having fun! I sure wanna hop back on the bike soon though.

April 3rd, 2013, 08:23 PM	#9
n4mwd ninjette.org certified postwhore Name: D Location: Palm Beach, FL Join Date: Oct 2010 Motorcycle(s): 2006 Ninja 250R, 2007 EFI Ninja 250R Posts: A lot. Blog Entries: 1	Rocker arm nuts = 12# Cam caps = 9# They are very easy to strip. __________________________________________________ My Ninja Blog Proud member of ABATE.My NYC Road Rage documentary - CENSORED!

Similar Threads
Thread	Thread Starter	Forum	Replies	Last Post
Rocker arm mod	JAG	2008 - 2012 Ninja 250R Tech Talk	4	August 25th, 2013 08:36 PM
Broke a damn rocker arm during valve adjustment.	SV_Hadder	1986 - 2007 Ninja 250R Tech Talk	7	April 3rd, 2013 03:00 PM
Missing Rocker arm and valve adjust screw/nut	Ragnar1x	1986 - 2007 Ninja 250R Tech Talk	45	May 22nd, 2011 09:28 AM
[roadracingworld.com] - Crutchlow Undergoes Successful Arm Pump Surgery On Right Arm	Ninjette Newsbot	Motorcycling News	0	April 8th, 2011 09:30 AM
WTB-rocker arm	yelve	Items Wanted	5	April 6th, 2011 05:26 PM