How to: Rebuilding of damaged rocker arms - Honda XR 500 R - year 1982 part 4.

Honda XR 500 R repair series
Hi.
This video shows - step by step - rebuild a motorcycle rocker arms from car rocker arms
Grinding - milling - drilling - welding
. . . for more interesting videos click ,, HERE "
/ @paulxchannel

[@scoc253]

*w0w. that's a lifetime rocker arm bearing!* 👏🏽🙌🏽

[@alexsoto5389]

now you are a true genius, you met the challenge that I gave you in the previous video about rebuilding some rocker arms but with bearings, no one on KZbin had done it, you are the first, greetings from Colombia, you deserve a bag of Colombian coffee.

[@blogplay196]

Класссс..приятно смотреть!!!!

[@bigbelconut]

They should have done that from the factory. I may try to make a set for my 600, I will have to make 4. You do nice work.

[@maxheadflow]

One thing to note is that you changed the radius of the rocker arm foot. In doing so you changed the cam timing. Since the radius is smaller. the duration is likely less. Back in the old days you could buy flat tappet followers for triumph twins that would increase the duration of the valve lft as the stock ones had a radius. Your roller is likely doing the opposite. Interesting fix tho.

[@peterjohnsracing]

I was about to say exactly the same

[@jonnoMoto]

I don't think it'll matter much, the new cam has different profiles to the original

[@NICK-uy3nl]

Cam duration will be slightly reduced; however, this engine can rev higher with less friction. Results: slightly less torque at low RPMs, more power at higher RPMs. A set of stiffer valve springs would also be a good choice with roller followers

[@maxheadflow]

@@NICK-uy3nl How much HP is eaten up with a shoe versus a roller in this case?

[@NICK-uy3nl]

@@maxheadflow- I would guesstimate 5% of overall engine power. Most of that gain will come at higher RPMs, where rolling friction of dry cam followers really go up, whereas roller followers maintain negligible friction throughout the rev range

[@barneyc4919]

The camshaft and the follower are designed as a single assembly, if you reduce the follower radius everything changes, total lift the same but how it gets there and back will change. Initial valve lift will slower followed by a sudden ramp up.

[@topmastermind]

Exactly. Innitial lift and closing timing are not thesame. He may get the engine running but cant get exact performance as the original

[@bigbelconut]

If he put everything back as the original nothing will change but reduced friction.

[@philippemariloussian5218]

Nice idea, unfortunately nothing is coaxial as holes done before welding. This is why methods exist to maintain milling process with surface or axial references. We see at the end that friction or rolling are not parallel. But finished with mistakes is far better than not finishing a project.😅

[@juanjumilla2639]

Be careful there is a scammer it is not paul x

[@suattasc9800]

My friend, thanks to your work, I did the same for my Dr350, it was very nice, thank you very much, greetings from Turkey.

[@TheSonofseventhson]

state of art work... never seen in youtube someone so tidy!

[@user-xf6sc1mk5h]

Отличная работа уважаемый Товарищь!) а я сейчас наоборот с рокеров ktm 640 убираю подшипник качения и заменяют его подшипником скольжения с blc покрытием для повышения надёжности данного узла в дальних путешествиях

[@cristianarad6637]

MERRY CHRISTMAS from Arad/Romania!

[@carloemiliozuniga]

congratulations! the finished rocker arms looks a lot like the LC4 rocker. awesome result!

[@raiderproject7728]

this is cool I like the way you work. if I had these complete tools I would definitely do it too greetings from Indonesia 🙏 don't forget to stop by friends 😁

[@InductionHead]

если бы вы были рядом со мной, конечно, мистер. Пол отнимет у меня много головы. Мистер Пол очень хорош в своей работе!

[@PavelVladimirovich86]

Первый раз вижу чтоб так не окуратно подошёл к решению, но идея хорошая.

[@motooilermotooiler9597]

I have nothing but utter respect to what you have done, especially I wanted, initially to go the same route in case of my Sherco ST320 engine. Apart from slightly different geometry of the contraption you have gotten, remember this bearing design is nothing but eternal - ST320 and some LC4 620,640 motors were plagued by these failing resulting in the whole engine failure due to debris ingestion. I bow to you and hope all is going to be all right - in the end you can replace them every 100hours. Cheers mate!

[@sloppyoppie]

Very cool. I dreamed of going the trick little bearing route on my '82 like that! And very cool high flow machine! Instead, I borrowed from the 3wheeler's and made oil injection ports directly to each journal. Two lines, routed though brake line, from two banjo's installed into the 2 "aux oil ports" on the right side cover to two holes drilled into the top of the rocker cover leading to the journal faces themselves. I restricted the rocker cover's (*edit*: head's , not rocker cover) stock oil inlet by just over 1/2 to both maintain good pressure throughout and to make it (literally) squirt onto the rockers rather than simply fill the pool (which still does fill). I don't know if the latter helped but the pressurized journal oiling absolutely made a difference- tho probably not as much as bearings would have lol. I primarily use the 500 for solo missions to Loreto from San Juanico, BCS via the E/W road (..it has a very hard job). It has not had a bit of issue w/either the rockers nor the journals since I did this several years ago and I push it, Baja style. (USD CR250 forks, .30 over, diy ported & polished, diy pipes, makuni swapped, uncorked, 12v'd etc)

[@PaulXchannel]

👍

[@tetrakite]

Amazing fix (as usual, should I say). This bike will be OK for the next 50 years.

[@c__TattinhNhi]

I don't understand why you have such great ideas

[@dannyjohnson2536]

Beautiful machining and handwork. 🤩

[@juanjumilla2639]

One of the most greates KZbin Chanels Is just Amazing your Job keep it up

[@davidcort2857]

A mechanical God at work.

[@muhamadramadhan2711]

you make rocker arm precision 👌good brother

[@dimisdnc710]

Excellent work!

[@mikhail5567]

Good Idea. Good skills. That is impressive.

[@chrisvozza6530]

Very nice! My most favorite yet

[@Waranus36]

Another great job from Paul. Just as usual ;). One of the good old Honda will be great again. Merry Christmas!

[@hpdepasse5997]

it's great work, as usual, know-how, imagination, beautiful tools, it's always a pleasure to see your videos. the cam does not push the tappet only in the center, I fear that a reduced diameter will also reduce the opening time and increase the speed of valve movement, and the weight of the moving assembly could become a concern at high revs.

[@Zt3v3]

That head that says "High Flow" is a KTM 625 or 640. I always wanted one of those for my ol' LC4.

[@ivanc251]

Superb work!!

[@coax.]

such a nice conversion to do

[@AndriRiefaldi]

Keren sekali Paman, impian ku mempunyai alat bagus dan lengkap seperti itu Dan ide cara sangat presisi

[@abdulmuis6991]

Mantap hadir nyimak video nya sahabat 🙏

[@raynyhus2026]

Cool tabletop piece the demonstrates the valve train operation.

[@eatingplaydoh]

Exquisite work.

[@vini5417]

Great job brow 👏👏👏👏👏

[@xandylanderx2508]

Você é um gênio !! 👏🏼👏🏼👏🏼

[@patrickbussius]

Das ist echte,perfekte,saubere Handwerkskunst

[@panosgiannosdiy1085]

i am so interested to see and hear that motor working . . .

[@hororr4409]

Good job! I also had a similar idea about the helmet, I wanted to repair the head from the Suzuki DR650, unfortunately, I didn’t get my hands on it yet

[@nikson1520]

Tenho uma Sahara 350 rfvc precisava fazer isso nela também ,good Idea brother congratulações.

[@viorelindeamna6405]

Bonne travaille Paul !👍👍👍💯💯💯💥💥💥

[@stephanelanglois6140]

very good job 👍

[@Patricks_Projects]

You need to regrind the camshaft when having a roller. You lost a lot of valuable lift early and late on the lobe now.

[@aodtoxic]

It looks like with old rocker arms valves was in the open position for a longer time.

[@allendesautels7379]

the real test would be back to back dyno results!! that would be an awesome conclusion to your engineering!

[@PaulXchannel]

In future videos

[@Speedandsoundmotorsgarage]

Nice machining

[@TuyenTran-os2gt]

Nó có thay đổi gì góc mở trên biểu đồ hình Sin không cơ, nó liên quan khá nhiều đến bí thuật của hãng

[@user-gt3xz6wo3o]

Awesome bro~!!!

[@alexsalazar2865]

Excelente trabajo yo lo hice para mí gn 250 use martillos de ford fiesta claro que sin la tecnología y recursos del maestro del vídeo felicidades

[@eliapratomo3023]

Merubah rocker arm dengan model roller sebenarnya bagus karena mengurangi gesekan, tetapi sepengetahuan saya harus merubah profil dari camshaf nya.. karena durasi buka tutup katup akan berubah apabila profil camshaf masih model lama.

[@husky9167]

Да профиль остается прежним и из за этого фаза открытия клапана будет меньше от чего и следует что двигатель потеряет мощность из за того что наполнение ТВС будет хуже

[@canalgaragem4tempos]

Acredito que vai precisar mudar o comendo também, pois a permanência das válvulas diminuíram. I believe you will need to change the eating too, as the permanence of the valves has decreased.

[@zardportugal]

Top job.

[@keithparady2594]

Absolutely genius killer work man

[@ezequielsilva2709]

Muito bom 👏👏

[@daviddanielstephenson2833]

What was normally a bullet proofe engine made bomp proofe, very nice job.

[@rogeriomigrantes5606]

Sensacional!!!

[@user-ey4cj4zy5p]

Good 💡👍

[@DersNoNem]

One thing yamaha done it right single cylinder under 155cc engine. The optimisation of using roller bearings in the engine head.

[@rafaelocd]

A ideia do vídeo era mostrar o trabalho de precisão. Mas era mais fácil ter trocado o balanceiro... Balancim roller e fricção são diferentes no aspecto de perfil, um e mais suave no caso do roller o came do ficção e mais pontudo e agressivo, isso aumenta muito a aceleração do conjunto, podendo quebrar. Resumindo na Eng nós não faríamos isso kkkk. Mas a ideia só vídeo era outra então tá valendo.

[@dmc5681]

You can’t just swap in a roller follower onto a sliding foot rocker without screwing the smooth valve motion. The cam itself is vastly different with a roller rocker setup. You dont need to plot out the valve motion You can visually see the closing is much more aggressive Also that weld is likely to crack

[@PaulXchannel]

Functional since 2001

[@riskiwiatanto]

How to know ideal timing valve & ideal lift valve before swap roller rocker arm without re dialling the engine?

[@lee4847]

Unfortunately you two don't have a clue. Best go to college or something. Do you want me to explain?

[@dmc5681]

@@lee4847 won’t be holding my breath

[@korrutustabel]

Nice machining and so on but try welding on some practice parts before going for real thing. I know, cast materials are bad to weld but holy hell, I hope this holds. A lot of force concentrators in this rocker build.

[@PaulXchannel]

🧠👍

[@anonymously241]

Happy merry Christmas PhoL🎄⛄ 🎅

[@ronimard]

Keren lah ini chanel

[@guidosamson682]

Nice but i would heve never done this. I would buy it for sure. Factory R&D has gone innthat for sure and you cant match it. But wel done nice job

[@amangtahecogot]

Sangat rapih proses perbuatannya

[@samuelassuncao]

Top demais esses vídeos, serviço de precisão imensa.

[@victorcardoso4516]

idea is good, but camshaft profile needs to change due to change to bearing.

[@user-xj2bm4df4zmoney]

太酷了！有沒有在買，想買一個放在家裡做裝飾！

[@user-xj2bm4df4zmoney]

這裡是我的用戶中文名字梁文國和連結youtube.com/@user-xj2bm4df4zmoney

[@huehueteotl03]

Muy buena idea

[@chikotrack8768]

Mantap bozz.....👍❤️

[@chikotrack8768]

Hadiah apa yang saya dapat dari anda?

[@Herzankerkreuz67]

Nice

[@iranalencar5925]

Serviço top

[@UA3USY]

крууть !!

[@bryanburrows7239]

I seem to remember flat tappet cams are different profile to roller cams ??

[@iurii-wind]

Ахренеть! Мастер! Best! 🤝👍💪👌🤙🇷🇺

[@BrianjSiehr]

Not sure what steel he used but the fork should be heat treated after reaming and getting it parallel to the cam surface. If not at least Rc 45, it will probably pean out the hole the roller shaft is staked in

[@user-tb3oz6op3d]

Супер!!!

[@Koodie2]

Does the added mass not affect the valve return speed at high rpm?

[@leejongkok13]

Hey Paul, try collaborating with a "Tekno Tuner HS Official", maybe he should work with you. lately he's been viral in our country Indonesia because at Christmas he was racing in tailan

[@MrLexnad]

Para cuándo parte 5 :) ???

[@firstielasty1162]

Nice job saving an antique...including the video of the camshaft.. I like XR's and have thought of doing something similar with an xr100, but haven't. I know you were not looking for cam timing perfection, but I wonder about the cam duration. The roller looks to have a smaller radius than the original cam follower pad surface, which would shorten the effective duration if measured at the valve. Does the different cam lobe make up for this? Or is it just close enough to work "pretty good"? The 82 xr500 probably had very mild cam specs and is tolerant of some "that looks pretty close" engineering. How does it run now?

[@rickhaass1133]

Thanks - was really wondering how it worked - how did she run - and could the max RPM be raised?

[@PaulXchannel]

More in future videos

[@robertoburromiapanino2659]

Great stuff Paul, Inspiration for the few old reed valve 500's I've been meaning to get around to. Can you give me more info on the engine the camshaft came from and was it 4140 steel you used for the rocker conversion? Cheers.

[@PaulXchannel]

Thanks. 1.4404

[@user-ml6qs5hw5b]

Идея хорошая,но фразы перекрытия изменяться и непонятно как будет смазываться игольчатый подшипник упорного ролика.

[@anthonyturton8091]

Another excellent vid . just found your channel tonight and subscribed. do you happen to know which car the roller rockers were off,? I like your approach of repair and reuse ,rather than just replace Happy christmas to you and all who read this comment . and have a nice day to anyone who doesnt do christmas.

[@johnwalker194]

The ones he used looked like smaller versions of VW 1.2/1.4 16 valve followers ! Maybe even vauxhall CDTI twin cam as used in combo vans and corsa diesels ? Think it was a Fiat design in those and were fitted to a lot of different makes of car !

[@anthonyturton8091]

@@johnwalker194 thank you

[@lucyferek]

Those looks exactly like INA followers for all PSA engines from 1999 to present. Especially all those HDI engines.

[@johnwalker194]

@@lucyferek yeah, could be the same ones I have seen over and over in many years of dismantling salvage vehicles ! I lose track of what and where, LoL ! The Peugeot units were also used in small Ford diesel models also !

[@anthonyturton8091]

@@lucyferek thank you

[@JackGladstoneHolroyde]

Couldn't you have built up the worn down surfaces with TIG and then ground to shape? I'm sure I've seen you do that before?

[@PaulXchannel]

I wanted to show another way of repair.

[@riskiwiatanto]

You not re dialling for ideal lift valve & ideal timing valve open & close....?

[@raulpadilla782]

Hi! I have an XR650L ¿ how tight has to be the valve rocker arm ?

[@amitmajumder1511]

👌👌👌👌👌

[@lrdisco2005]

Could you achieve higher rpm with this design

[@yoceflkorti3800]

أنت بالفعل ذكي جدا لكن هل انت ذكي لكشف من هو الإله الحقيقي الذي خلق السماوات والأرض في 6ايام ولم يتعب بخلقهن

[@Mike-gr2ok]

The earth and planets took billions of years to form, its simple science, nothing to do with God's my friend

[@rashidnaga]

forged vs welding i think forged its batter then welding.its luck stuff can survive.

[@Okipouros]

What @maxheaflow said and phillip, but most importantly you didnt heat treat it, and its too soft like to last

[@karstenjovanovic578]

Is this Set of cam and rockers fix for a xl 500 r '85? And what will it cost? In €🤔

[@HabibKhan-gz8hf]

Salam hy

[@jrsqlc]

Great content @paul X I would like to contact you about repair work. How do I reach you sir?

[@trillionerkrimtat]

Бро хочу заказать себе такиеже у вас

[@Fau8]

Друга на Яве похожий движок

[@c__TattinhNhi]

👍👍👍♥️

[@c__TattinhNhi]

doing such a thing does it deviate from the manufacturer's camshaft?

[@TheMotorongo]

What is that digital device that shows a measure of the cam..???

[@PaulXchannel]

Time?

[@aldoblasigh7533]

Vw armrock cam roller