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Cam failure

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After suffering with high oil consumption all summer and all but loosing compression on the left pot I took off the head and barrels on my 1970 Roadster to find the cause, expecting any or all of the standard disasters. So far I have found replacement bronze valve guides on the inlet with petrified rubber seals but on guides that don't have a lip to secure the seal. That seems odd. Then I found it had bronze guides for the exhaust valves as well. This I've understood is a complete no no and that only iron should be used. The rings and bore looked fine but a measurement might prove otherwise. The right side barrel stud was brocken and the copper gasket in a very poor state.  So all in all I found all of the standard disasters.

What I didn't expect to see though was that one lobe on the right cylinder side of the cam was completely worn away. The others looked really quite healthy and the cam follower for the worn lobe didn't look all that bad either. The strange thing is the bike wasn't running that bad at all and I haven't had to keep adjusting the tappets so it could well have been like that for years. Does anyone know what could cause just one lobe to wear like that? (See pic)

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 Too long between oil changes. etc etc

Sometimes the engine can be noisy when the cam is/has failed. Other times it will give no sign of  failure, the engine exhibiting no undue noise. The engine has obviously been apart at some stage in the past fifty odd years (at least the top end has)  If the cam has been replaced in the past it is possible that the cam run in procedure was neglected and/or the followers weren't refaced at the same time.  1970 bike, does it have the spin on filter?    

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Once you're thru the hardening the cam will disappear pretty quickly. Suprising it ran at all really. All sorts of reasons for failure from poorly manufactured camshaft to head oil feed failure to poor assembly.

Bronze guides are fine for exhaust. Seals can be pushed over guides without a lip and will stay for a while. Even floating around, the seal will do a little bit.

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The tappet clearance is measured on the base circle so disappearing lobes aren't noticeable. The clue is usually on a magnetic drain plug if one is fitted.

It usually seems to be the drive side exhaust lobe which has the most marginal lubrication, but once a lobe has scuffed, it can indeed disappear quite quickly. It is indeed remarkable how well they can run with presumably one cylinder doing most of the work.

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Are your guides perhaps Colsibro (a copper/nickel/silicon alloy, rather than copper/tin)?

I have a set in my Fastback, run without oil seals on either inlet or exhaust. I can't comment on really long-term use, but three years' experience suggests minimal effects on oil consumption, etc. 

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Most of the BIG name Norton Engine restorers and tuners recommend fitting Colisbro guides all-round. The RGM set comes with inlet guide seal lip grooves and boot seals whereas the exhaust have plain shoulders. Care must be taken when fitting Colisbro guides as the inner bore can narrow and need reaming back to the correct running clearance. If this clearance is poor then the valve stems will pick up in the guide which in turn can overload the camshaft.

The downside of a worn camshaft lobe(s)  is the trail of very abrasive debris pumped around the engine as a consequence. An inline filter will have helped, if fitted, but I would be looking at changing the main bearings and possibly the big ends while the motor is dismantled. The oil pump and any bushes would probably need checking out as well.

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Thanks everyone for your very helpful replies

The last time the head was off and the cases were split was 1981. Although I did a lot of the work myself, youthful lack of experience and ignorance (and no internet) led me to take technical advice and buy parts from all sorts. The bike was in storage for most of the time since the late 80s until a few years ago when I started pulling it apart once more. I have been quite amazed by my poor assembly skills but moreso by the plethora of wrong, poorly fitting and badly made patent parts I was convinced to use by my local british bike parts supplier in SE London. Sadly, also, I don't remember well exactly what I did or what parts I used. 

The valve guides were almost certainly patent parts and not Colisbro.  I had two completely different seals that someone probably convinced me would be fine. I remember fitting new valve springs, although the originals were probably fine, and I think the extra strength from the springs and not using the correct start up procedure after the rebuild knackered the original cam. I replaced the cam and the cam followers, which I remember lapping into the follower bores with grinding paste by hand over many evenings because the new ones were too large (more patent parts maybe?)  The replacement cam was not the same as the original cam, although the profile may have been, and there was no way to fit the original timed breather disk and once again I was convinced this would  be fine and that the engine would breath naturally. Of course it didn't!

It may be a bessing for the bike that I have to pull the engine out and do it properly with the correct well made parts and 43 years more experience. I dont remember if I changed the main bearings but I certainly will now. I changed the big end shells but they deserve a another look. I had the oil pump rebuilt by RGM a while back. I've changed seals and checked everything in the timing case and primary case so its only really the head, barrels and inside the crancase work to do.  I may as well do the crancase mod drilling and moving the oil galleries to assisist the beathing too, but should I stick to having no timed disk breather on the drive side of the cam and keep my yamaha type PCV that seems to work quite well?

I think I'm looking forward to this now I've got over the initial dissapointment of seeing the cam. Not sure though....

 

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In the 1970s the factory fitted a soft cam, I questioned this at the time with the factory, they said the cams were the same material as they had always been, what they didn't say their new hardening process actually made them softer!! So 1970s saw a whole fiasco of soft cams from the factory (I know the 'hard' way). AS Richard says above-you adjust the tappet gap on the BACK of the cam. So the cam could completely disappear, but your tappet gap will stay the same. The other notice of a worn cam is a lack of top end performance. Loosing the timed breather is no big deal, BUT you must have some breathing-see Commando Service Notes for 750 breathing.

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It is not soft cams that fail, but Norton's ever increasing desire to produce harder and harder cams and followers. The race to ever increasing hardness was their undoing, due to an odd unrelated comment I made to a hard facing company it resulted in uncovering on why cams fail. 

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Apart from the fact that no one seems to have a 1S standard cam available at the moment, now I'm wondering what to do that might avoid another failure. There must be more to avoiding a short cam life than assembling it with the right lube. Graphogen or Ultra Lube seem to be RGMs options. Last time I must have used molybdenum grease I think being as I still have a tube of it. Getting some revs on to spash a bit of the Castrol 20/50 on it at first start up seems important too.  Chilled iron, billet, nitriding steel, all seem to be cam options but which one to get, who makes what and where to get them remains a mystery.  Flat lapped and polished, or radiused cam followers are also options but whats the difference between them?  Is there one formula that works best?

I'm not really getting why it seems so easy to destroy a cam in a Norton. I remember reading an article by chance some years ago about how to go about installing and running in a Norton cam to give it the best chance of survival. I have no idea where I came accross it though. It's a very expensive installation to get wrong. 

Yes, come on Ashley, spill the beans. 

PS I forgot to answer a question from before: No the bike doesn't have an oil filter. Just the good old mesh and magnet on the drain plug. This is why I think the cam may have been worn like this from before I put it in storage years ago as there have been almost no traces of metal patricles on the magnate in the last 2 years. It has only done 1000 miles since I put it back on the road but I have still changed the oil regularly.  

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Cam followers should have ground finish. For Norton camshafts, grind flat, square to the follower body and in the direction of travel.

Camshaft is lubricated by oil running down the pushrods tunnels. It should be a river. Correct installion of cam followers and rocker spindles is essential. Likewise a good oil pump, good seals and no blockages in feed pipes, unions etc.

Before starting after a lengthy layup (winter), squirt some oil down the pushrods via the exhaust tappet covers. This also applies to newly assembled engines. Moly grease, aaargh, no. Proper assembly paste if the engine is going to sit around a while before you start it, otherwise oil is fine.

The camshafts and followers that Andover sell are fine. I wouldn't look anywhere else.

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The earlier bikes like the 88/99/650  had little issues with cam wear even though  the rocker boxes recieved only a dribble of oil from the very low pressure system. MY 99 is still giving better than new performance on the orriginal parts after 50k miles. I put this down to a mild state of tune ,  a functional cam trough and a bit of wet sumping that ensures the cam gets a good splash immediately on starting. I dont fully drain the wet sump now but leave plenty in there . Hard valve springs and fierce  cam profiles must be a factor. It should be possible to end feed the cam and have oilways in the cam flanks? perhaps thats the way to go ?.

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and engine oil with proper zinc content will help too.

 


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