Case Work on Viragos

This one makes me a little nervous as it involves the back-and-forth shipping of empty cases: bulky and fragile. Be sure to empty all fittings and just send in the basre aluminum with the cast-in iron parts. Bolt them securely together. Lay multiple layers of bubble wrap around them. Fill with styrofoam "peanuts" or expanding foam. Anything that must be removed or scraped off on our end will incur more costs to you -- if you expect to get them back.

What we'll do:

Chemical dip (unless you ask us to skip it) to strip all grease and dirt. Blasting with several grades of beads, ending with walnut shells. All oil passages will be blocked at this stage. Optionally, we'll powder-coat black or silver inside; your choice outside. Your main bearing bores will be hard chromed down to 90mm ID and the 6308 bearings of your choice will be seated. Bearings that have oiling channels and oil holes could have passages bored into the transmission feed lines in order to make sure that there is no starvation problems as stock these bearings are fed by splash. Case spigots bored to appropriate girth for your application. We'll look into a maximum bore cut with snug-fit aluminum rings for smaller sizes included. All potential obstacles to long stroke cranks will be fly cut off; all iffy protrusions. New dowels for oil passages and a plugged tap hole for those that want to run an oil cooler from near the pressure release, rather than off the filter cover.

That's all that comes to mind at the moment. No prices set. Reckon on $65 each way on shipping. I must get quotes on plating and powder coating and prices on various bearings. All of these procedures take place elsewhere. Before you ask, do NOT ship complete engines for us to build. This location is not zoned for it. And we can't afford to farm it out. Shipping and transportation add up and no matter how good of friends we are with third parties, they won't work for free.

Rockers come in two flavors, and they are dispersed throughout the series seemingly at random. We pull apart motors and find things like 700s with all hardened rockers and 1100s with none. Some engines have one, two, or three hard rockers. Most have none. The hard rockers are not available from Yamaha: if you order a rocker, 700 to 1100 and the XVS1100, you will get a unit with an unhardened pad where it meets the cam with a largish oil hole dead-center.

Our hard rockers have a layer about 2mm thick of hardened steel. The oil feed is in the arm a little "upstream." Never have I taken apart a head and found these with the least bit of wear. Sometimes I find perfectly convex rocker pads and cam lobes worn down almost to the base circle. How a bike in this condition ran is a mystery.

Anyhow, the typical rocker found has a large central oil passage, and no discernible hardening. These rockers are almost always too worn to run. Some are extremely concave and it gives me pause to wonder how the rider could tolerate the noise. Worn rockers are almost always associated with flattened adjusters and dished valve tips. The adjusters (AKA tappets) should be hemispherical in section where they meet the valve tip. They do appear to have a very thin layer of hardened material. In a pinch, it is possible to wrap the threads against damage and clamp them in a drill. Then carefully apply the edges to a whetstone or knife stele until they are once again convex. At best, this is temporary, as you have almost certainly worn away any hardening. These can typically be acquired new for less than ten dollars a piece. In the future, I hope to be able to offer a kit containing adjusters, jam nuts, and valve keepers -- all in titanium. Not soon.

Holed rockers will work indefinitely if the engine is kept full of fresh oil and the bike is never revved. A cam with over .425" lift or excursions past stock red line will wear the rockers into uselessness in no time. For performance riding, hard rockers must be used. If you study the websites/catalogs of Megacycle and Web Cam, you will find rocker welding services. Typically these run a hundred dollars per rocker - exchange. The finished product looks like these we are offering. You may be lucky and have all hard rockers. Perhaps a couple. Likely none. Performance cams dictate their use.