Destructo 7 Posted June 8, 2022 2003 trx500FA Finished getting all the new parts and started to slap this thing together but I am stuck at the push rods. For whatever reason i can't get them to line up with both the rocker arms and the followers. I followed the manual and when I place the pushrods on the follower they push the follower all the way down to the cam, and then fall over pushing the gaskets little pushrod holder bit downward. When I place the valve cover on the pushrods don't line up with the rockers ( due to the gasket not being super strong and not holding them where they need to be) the manual says to line them up with my finger. But my finger prevents the cover from sliding down enough to meet the rods. I can't fit my fingers deep enough in the adjustment cover hole to even touch them. I browsed around and it seems I'm the only one in the world who's got this issue. What am I missing here ? Share this post Link to post Share on other sites
shadetree 5,501 Posted June 8, 2022 21 minutes ago, Destructo said: 2003 trx500FA Finished getting all the new parts and started to slap this thing together but I am stuck at the push rods. For whatever reason i can't get them to line up with both the rocker arms and the followers. I followed the manual and when I place the pushrods on the follower they push the follower all the way down to the cam, and then fall over pushing the gaskets little pushrod holder bit downward. When I place the valve cover on the pushrods don't line up with the rockers ( due to the gasket not being super strong and not holding them where they need to be) the manual says to line them up with my finger. But my finger prevents the cover from sliding down enough to meet the rods. I can't fit my fingers deep enough in the adjustment cover hole to even touch them. I browsed around and it seems I'm the only one in the world who's got this issue. What am I missing here ? i've only worked on a couple trx500fa, they have the over head cam..correct ?, did you install the cam facing the lobes the correct way ?, you are right, the rocker cover does not give ya much room to get the push rods room to line up them up with the rocker cup ends, if i remember right when i did it, i had to use a flashlight to peek into the rocker box to make sure the push rods were in the rocker cups before i bolted the rocker box down. Share this post Link to post Share on other sites
Destructo 7 Posted June 8, 2022 i installed the cam as per the manual with the little line level with the head while at TDC. the cam is offset on the head and the rods are super tiny. Do the pushrods suction to the rocker before i set it down? the followers can really only go in one way with the cup side up and the flat side down or else they'd just get jammed up on the cam lobes. Share this post Link to post Share on other sites
shadetree 5,501 Posted June 8, 2022 4 minutes ago, Destructo said: i installed the cam as per the manual with the little line level with the head while at TDC. the cam is offset on the head and the rods are super tiny. Do the pushrods suction to the rocker before i set it down? the followers can really only go in one way with the cup side up and the flat side down or else they'd just get jammed up on the cam lobes. yes, followers face flat side down, rest on cam lobes., sounds like you got everything correct, just having a hard time getting the rocker box down on the top of the push rods. Share this post Link to post Share on other sites
Destructo 7 Posted June 8, 2022 yeah thats right.... and my fingers are too fat and short to reach the little buggers to line them up haha. i can get the cover down all the way but the rods miss the rockers 1 Share this post Link to post Share on other sites
Fishfiles 17,794 Posted June 8, 2022 Just now, Destructo said: yeah thats right.... and my fingers are too fat and short to reach the little buggers to line them up haha. i can get the cover down all the way but the rods miss the rockers I think we are onto the problem " short , fat fingers " , not the first time that has caused a problem , LOL Share this post Link to post Share on other sites
Destructo 7 Posted June 8, 2022 Yes... wife likes, Honda hates haha i feel like a flat tool with the shape of the pushrods spaced properly would be my only out here... but there has to be a better way Share this post Link to post Share on other sites
shadetree 5,501 Posted June 8, 2022 12 minutes ago, Destructo said: Yes... wife likes, Honda hates haha i feel like a flat tool with the shape of the pushrods spaced properly would be my only out here... but there has to be a better way try resting the push rods at the correct angle and spacing with the engine angled by maybe jacking the frame up so the push rods stay in place while you set the rocker box down on them ?. i was not fond of these types of rocker boxes with the rocker design when i did them. another reason i hate the trx500fa !...lol. Share this post Link to post Share on other sites
Destructo 7 Posted June 8, 2022 hmm good idea, i have the whole thing on 4 jack stands... i will lower the right hand side tonight to the ground and see if that works. durable but dumb design... they should take a lesson from the amc/jeep 4.0 lol Share this post Link to post Share on other sites
shadetree 5,501 Posted June 8, 2022 6 hours ago, Destructo said: hmm good idea, i have the whole thing on 4 jack stands... i will lower the right hand side tonight to the ground and see if that works. durable but dumb design... they should take a lesson from the amc/jeep 4.0 lol no..they should takes lessons from us guy's that fix them all the time !..if anyone should know how they should be built ?..IT'S US !..LOL. Share this post Link to post Share on other sites
shadetree 5,501 Posted June 8, 2022 i can't count on all my fingers an toes on how many stupid designs i have seen on honda atvs..some of them just make ya shake yer head..and ask..why ??!!..lol. Share this post Link to post Share on other sites
Destructo 7 Posted June 8, 2022 there has to be some honda engineer dude somewhere like: "it is wisest to do things the most difficult way possible, it is our duty to use dissimilar metals in high tension high stress/strain environment" "hondamatic run good, until 30 cent part fails then we get to sell another hondamatic" "cant they just rebuild the hondamatic?" "no because we will ensure we manufacture a special seal for it and never sell it to anybody!!!!!" "Oh you so wise engineer-san! yes we must follow this path!" 1 Share this post Link to post Share on other sites
shadetree 5,501 Posted June 8, 2022 2 minutes ago, Destructo said: there has to be some honda engineer dude somewhere like: "it is wisest to do things the most difficult way possible, it is our duty to use dissimilar metals in high tension high stress/strain environment" "hondamatic run good, until 30 cent part fails then we get to sell another hondamatic" "cant they just rebuild the hondamatic?" "no because we will ensure we manufacture a special seal for it and never sell it to anybody!!!!!" "Oh you so wise engineer-san! yes we must follow this path!" its called job security !!..rofl. 2 Share this post Link to post Share on other sites
