Rocker arms - sorry guys something to worry about

Clive

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It is known that the rocker arm bearings can fail - bind up on the shaft - so it really is something you need to check otherwise the consequential damage can be a lot more expensive.

My 2017 Euro4 CR at 13500miles is one of the latest and best incarnations of the model and I seem to have been lucky with no major issues so I suppose I assumed that my rocker arms were probably ok. First symptom was a rattly noise which was new. I checked the timing chain tensioner and it was ok so I decided to pop the rocker cover and check the rocker adjustment like we need to do every 2 years.

I used the excellent CNW guide and it is fiddly but not difficult to do. On exposing the rocker arms I discovered that one of the inlet rockers was wobbling on the shaft. for those who have not looked at the setup the push rods come up through the head with an oil feed hole through the middle which feeds up through a hole in the rocker adjuster screw ball end which then feeds through a hole in the rocker into the centre on the bearings. The bearings are 2 plain bearings around 20mm outside 16mm inside and 10mm wide. they are pushed into either end of the rocker. The angle of push is a quite offset so the loading is not direct. The bearings at the one end had drifted into the rocker up against the bearing at the other end. This then blanks off the oil feed. The bearings had not seized onto the shaft my thought is that the irregular pressures and poor bearing fit had caused it to deform.

The canted rocker then started wearing the side of the mounting post, the roller, and damaged the end of the valve stem.

So really this should require new rockers, mounting block, valve. Big job. Expensive job. Hence this thread to recommend that you make sure this doesn't happen to you.

New new Norton don't have any rockers on the shelf and won't tell me if they have been updated. Thanks guys your support of the Norton owning community who helped you get the problems of the 961 sorted is just great. Don't blame Scott he's a great guy but hamstrung by the company's policy and will let me know price as soon as rockers are available. Just remember that when bikers see a 961 on the back of a recovery truck or hear that a friend of a friend's 961 is bust they can't tell if it's a TVS or G*rner....

Thiel motorsport in Germany do a refurb service and have a fantastic reputation for their engineering. I am waiting to see if they have spare rockers and can refurb.

Rocker arms - sorry guys something to worry about
Rocker arms - sorry guys something to worry about
Rocker arms - sorry guys something to worry about
Rocker arms - sorry guys something to worry about
Rocker arms - sorry guys something to worry about
 
It is known that the rocker arm bearings can fail - bind up on the shaft - so it really is something you need to check otherwise the consequential damage can be a lot more expensive.

My 2017 Euro4 CR at 13500miles is one of the latest and best incarnations of the model and I seem to have been lucky with no major issues so I suppose I assumed that my rocker arms were probably ok. First symptom was a rattly noise which was new. I checked the timing chain tensioner and it was ok so I decided to pop the rocker cover and check the rocker adjustment like we need to do every 2 years.

I used the excellent CNW guide and it is fiddly but not difficult to do. On exposing the rocker arms I discovered that one of the inlet rockers was wobbling on the shaft. for those who have not looked at the setup the push rods come up through the head with an oil feed hole through the middle which feeds up through a hole in the rocker adjuster screw ball end which then feeds through a hole in the rocker into the centre on the bearings. The bearings are 2 plain bearings around 20mm outside 16mm inside and 10mm wide. they are pushed into either end of the rocker. The angle of push is a quite offset so the loading is not direct. The bearings at the one end had drifted into the rocker up against the bearing at the other end. This then blanks off the oil feed. The bearings had not seized onto the shaft my thought is that the irregular pressures and poor bearing fit had caused it to deform.

The canted rocker then started wearing the side of the mounting post, the roller, and damaged the end of the valve stem.

So really this should require new rockers, mounting block, valve. Big job. Expensive job. Hence this thread to recommend that you make sure this doesn't happen to you.

New new Norton don't have any rockers on the shelf and won't tell me if they have been updated. Thanks guys your support of the Norton owning community who helped you get the problems of the 961 sorted is just great. Don't blame Scott he's a great guy but hamstrung by the company's policy and will let me know price as soon as rockers are available. Just remember that when bikers see a 961 on the back of a recovery truck or hear that a friend of a friend's 961 is bust they can't tell if it's a TVS or G*rner....

Thiel motorsport in Germany do a refurb service and have a fantastic reputation for their engineering. I am waiting to see if they have spare rockers and can refurb.

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Hello Clive , Are you going to do somethiing with the valve ? I see the flat spot on the roller . Is that side load wear on the rocker towers ? Ollie mentioned that there is usually too much side play in the assembly and should be minimised with shims on re-assembly . If they (manufacturer) had closer tolerances this shouldn't be an issue ? Did you have more than one rocker doing this ?
 
New Norton were looking into this, as they approached Theil, wanting to buy a number of his kits....I assume to copy and paste. Eitherway, Theil (Thiel...I can never remember) is certainly the way to go.
 
Don’t lynch me for saying this.
But who is actually the engineers and ones responsible for all the upgrades on the new 961?

Many want to give TVS the credit, but I say no. It’s the people of this forum and the owners that have addressed issues within.

So I then ask why? Why can’t TVS ever give a direct answer as to what will and will not work on our bikes. They surely know this. If all of the parts are interchangeable or can be swapped without machining, then offer the parts so ones who are having issues or want to prevent issues from happening.
 
I am in conversation with Thiel - obviously to swap rockers is nothing like the effort of a valve replacement but through lack of space and time I would have to pay someone to get this done so it is very tempting to risk the valve as it is.

If not replace then the side supports really need to be milled flat and shimmed. It seems that considering the offset there is not enough consideration of the offset/side loading. A CNC alloy rocker with inset bearings seems the ideal to me. I have only looked at the other inlet and that is going the same way.

I suppose if you use cutting-edge never-before used technology like rockers we should expect issues:rolleyes:
 
I suppose if you use cutting-edge never-before used technology like rockers we should expect issues:rolleyes:
You're right!
It's a real disappointment that Norton couldn't get this late 19th century cutting edge tech straight in the 961 engine.
They probably knew how to do it right, but just decided to do it cheap instead, to save money.
My have to blame Kenny Dreer for this one.
Sad.
 
I am in conversation with Thiel - obviously to swap rockers is nothing like the effort of a valve replacement but through lack of space and time I would have to pay someone to get this done so it is very tempting to risk the valve as it is.

If not replace then the side supports really need to be milled flat and shimmed. It seems that considering the offset there is not enough consideration of the offset/side loading. A CNC alloy rocker with inset bearings seems the ideal to me. I have only looked at the other inlet and that is going the same way.

I suppose if you use cutting-edge never-before used technology like rockers we should expect issues:rolleyes:
Ollie said .004" is good side play. There should have been 2 thrust washers per side of rocker arm on your assembly .
 
Yes 2 'thrust' washes but the side of the rocker is hardly a bearing surface.

New development just had Norton call me up (thanks Scott) who said that the new rockers will be available at £86 each. They are warrantied so I am thinking that New New Norton were aware of the rocker issue so these will be improved. And fit the shafts? Might be a bad move but it could be a way of finding out one way or another if they have changed. Worst case take a hit for the troops and they go to Thiel for his mods.
 
Yes 2 'thrust' washes but the side of the rocker is hardly a bearing surface.

New development just had Norton call me up (thanks Scott) who said that the new rockers will be available at £86 each. They are warrantied so I am thinking that New New Norton were aware of the rocker issue so these will be improved. And fit the shafts? Might be a bad move but it could be a way of finding out one way or another if they have changed. Worst case take a hit for the troops and they go to Thiel for his mods.
My guess is that if they have sold/warrantied them then they will fit. The bad press that they would get from routinely/knowingly selling parts that they are aware will not fit would be significant.

Despite what legalese was used previously, I think it is at the point of purchase we should ask the ‘will it fit’ question and suspect the answer will be forthcoming. The fact they will not divulge what technical changes have occurred is a different matter.

My Guess is that their approach will soften over time. New system, new people, new internal rules. Things change/develop as they bed in.
 
Yes 2 'thrust' washes but the side of the rocker is hardly a bearing surface.

New development just had Norton call me up (thanks Scott) who said that the new rockers will be available at £86 each. They are warrantied so I am thinking that New New Norton were aware of the rocker issue so these will be improved. And fit the shafts? Might be a bad move but it could be a way of finding out one way or another if they have changed. Worst case take a hit for the troops and they go to Thiel for his mods.
Are you getting new shafts as well ? ( I would )
 
I would not leave that valve stem. Why put a new roller rocker on a gouged valve stem tip?

The tip of your valve with the pressure of the spring will put you right back to where you are now.

The roller needs to “roll”.
 
Yes 2 'thrust' washes but the side of the rocker is hardly a bearing surface.

New development just had Norton call me up (thanks Scott) who said that the new rockers will be available at £86 each. They are warrantied so I am thinking that New New Norton were aware of the rocker issue so these will be improved. And fit the shafts? Might be a bad move but it could be a way of finding out one way or another if they have changed. Worst case take a hit for the troops and they go to Thiel for his mods.
I have dealt with Scott a number of times, and the reality is - he is very keen to assist with any reasonable request made.

(And I still can't wait for the day one of these things has SB written on it 🤣
 
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Hi Clive, are you saying the areas you've arrowed are wear? Or is that machined so that the surface is perpendicular to the shafts?

Rocker arms - sorry guys something to worry about
 
I've adjusted my clearances, but never delved further, but agree, this is concerning. I'd also be interested if the above is wear or machined....I'd guess machined, but?

To me, this looks like wear:
Rocker arms - sorry guys something to worry about



I'd also be interested in what Theil have done to improve the rockers, like wise with Norton if they indeed have improved them. I'd be a little annoyed to buy from Norton only to find they are identical, albeit new.

Regarding the valve tip, I'd carefully dress it, catching as mush swarf/filing as I could and adjust the valve clearance accordingly upon re assembly....assuming that the rocker posts etc are ok.

I think we'll all be watching with interest on this one Clive!
 
What you can see on the 'posts is indeed wear. This is what I'm trying to impress on owners - a rocker swap is easy - can be done in an hour or two with no specialised tools. Once something else gets damaged then its a whole new ball of fish. It does look a bit worse because the edge is raised. Tried to mike it up which is tricky but looks like it could be ten to twenty thou and it is not parallel with the post because of the canted rocker so what it really needs is taking out, milling and shimming which I will do.

With valve stem I'm really torn - the surface of the valve stem top almost looks as though some case hardened surface has come off but is it case hardened or could i polish it down a bit? Votes?

Anyone give me an idea of how long they would expect to take the engine out to lift the head?
 
I would definitely change that valve. If you leave it, it’ll chew the roller. If you dress it, you may well dress away the hardening.

Are you sure the engine needs to come out to lift the head?

If so, you may as well strip the whole motor and blue print / ‘Thiel-ize’ it.

Winter is coming. What else were you gonna do ?!
 
Good point, it probably is case hardened..and lash caps probably aren't an option. Tough one. You may get away with dressing if you don't go through the case hardening completely...but really difficult to tell.

I recon Stu is your man on engine removal times....
 
No Nigel I don't want Thiel's big bore kit upgrade and an SCS ECU replacement to set it up so just stop going on about it ok?

Anyone know if the head can be lifted with engine in-frame?
Yes , head comes off in frame .
 
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