TW200 Forum banner

1 - 13 of 13 Posts

·
Registered
Joined
·
69 Posts
Discussion Starter #1
I have an 06 that Im currently doing a full resto mod too.

as the title says the rocker shaft has a bolt and easy out stuck into the rocker shaft. Ive tried several carbide bits and that easy out is not even getting a scratch barely.

Question is, does oil need to feed through that shaft in order to oil the rocker arm or is it going to get sufficiently lubricated from splashing up there?
 

·
Registered
Joined
·
6,067 Posts
Hi Tyler,

Sorry to hear about this problem. Is the rocker shaft still in the head, or were you able to get the shaft out? How much of the broken bolt is protruding from the end of the shaft?

Brian
 

·
Registered
Joined
·
7,220 Posts
The rockers are oiled by splash from the sides and from a little hole on the top.

The hole in the center of the rocker shaft is threaded so one can screw a bolt into it and then use a slide hammer to remove the shaft from the head.

The two shafts are not interchangeable.

P7230042.JPG P7230043.JPG
 

·
Registered
Joined
·
13,795 Posts
The bolt has broken off flush with the shaft

The question is, does the passage in the shaft need to be clear in order for oil to lubricate in there?
Nope, the threaded holes are only for removal and installation of the rocker arm shafts and no oil "passes through" as it were. There is no other inlet or outlet other than these threaded holes. You will, however, may need to remove these shafts in the future if needing valve component repair or replacement, especially if the rocker arms themselves need to be replaced for whatever reason.



Partially removed. The shaft with the curved cutout above is the one with the slots below. This is so you can turn it because the head bolt passes through the passage next to this curved part.



 

·
Registered
Joined
·
7,220 Posts
The bolt has broken off flush with the shaft

The question is, does the passage in the shaft need to be clear in order for oil to lubricate in there?
The answer is no.
Oil goes up the hole the right rear head bolt is in into the center of the camshaft and the squirts out the 4 little holes lubricating the rockers and the bearings the camshaft rides in.

PA290026.JPG PA290024 (2).JPG PA290025.JPG oiol flow 1.jpg
 

·
Registered
Joined
·
6,067 Posts
The bolt has broken off flush with the shaft

The question is, does the passage in the shaft need to be clear in order for oil to lubricate in there?
Sorry Tyler, but that is tough one. Here are the options as I see it

1. Have a machinist see if they can drill it out enough to thread in a smaller diameter bolt.
2. As Peter suggested, take it to an EDM shop that has a "hole popper", and see if they can EDM a hole big enough to thread in a smaller diameter bolt.
3. Take it to a welder to see if they can weld an extension piece onto the broken bolt/end of the shaft.

If any of the above are successful, I would suggest heating up the head (aluminum) before trying to extract the shaft. If none of the above are successful, then:

4. Put it back together and let the next owner deal with it :eek:.
 

·
Registered
Joined
·
7,220 Posts
Depending on how desperate you are to get that rocker shaft out, after a lot of careful measuring, I bet one could drill a hole in the head and take a long punch and drive the rocker shaft out with a hammer. (Admiral is gonna love that!)

The shaft looks about level with the top fin, maybe just a tad below.
P7240045.JPG

And just inside the head bolt boss. Make your own measurements. I only "eye balled" it.
P7240046.JPG

Afterwards plug the hole with JB Weld, or tap the hole and red Loctite a bolt in it, or have a welder close it off. Or look for a cheap head on ebay -- shop TW's, XT's, TTR's, etc. as a lot of the heads are interchangeable and some can be had dirt cheap. And then there is always take it to a machinist but I bet but that could get expensive.

Anyway, my 2 cents worth. I am curious, why are you taking it apart?
 

·
Registered
Joined
·
379 Posts
Lay a suitable size nut in there and blast it hard/hot with a MIG welder. Then jump on it quick with a socket and the broken shank should thread right out.



Sent from my SGH-I337M using Tapatalk
 

·
Registered
Joined
·
379 Posts
Just make sure the ID of the nut only exposes the shank/easy out remains.

You can even tack/tack/tack it slowly first to build a small tower off the center ... then slip the nut over top of that weld the nut on.

Sent from my SGH-I337M using Tapatalk
 

·
Registered
Joined
·
69 Posts
Discussion Starter #12
Thanks everyone with suggestions.

I did think of the drill out the other side, but concerned about the head bolt hole.

EDM machine sounds interesting.

But Im just gonna leave it untill i absolutely need to take it out.

I will create a new thread soon to show everyone the rebuild. I have lots of pics.

Thanks again.
 

·
Registered
Joined
·
69 Posts
Discussion Starter #13
Depending on how desperate you are to get that rocker shaft out, after a lot of careful measuring, I bet one could drill a hole in the head and take a long punch and drive the rocker shaft out with a hammer. (Admiral is gonna love that!)

The shaft looks about level with the top fin, maybe just a tad below.
View attachment 154209

And just inside the head bolt boss. Make your own measurements. I only "eye balled" it.
View attachment 154217

Afterwards plug the hole with JB Weld, or tap the hole and red Loctite a bolt in it, or have a welder close it off. Or look for a cheap head on ebay -- shop TW's, XT's, TTR's, etc. as a lot of the heads are interchangeable and some can be had dirt cheap. And then there is always take it to a machinist but I bet but that could get expensive.

Anyway, my 2 cents worth. I am curious, why are you taking it apart?
Im doing an engine rebuild and wanted to lap the valves.

As per the manual it says to remove rocker shaft before the valves. Which i figured out isnt neccesary.
 
1 - 13 of 13 Posts
Top