I'm working on a 94 Evo. Base gaskets have been getting progressively worse so I finally broke down and decided that replacing the base gaskets would be easier than continually cleaning up oil.
Bought a top-end gasket kit and all was going well untill I reassembled the heads/rockers and re-inserted the pushrods. The motor has an Andrews EV46 cam and Andrews adjustable pushrods.
The pushrods were marked during disassembly and were reinstalled back where they came from. While turning the motor over by hand, both exhaust pushrods bent. Checked the relative length of all 4 pushrods and confirmed that they were all in their correct spots.
After pulling them all back out I got a set of Screamin Eagle Easy Install adjustables and put those in. Adjusted them according to instructions, let the lifters bleed down for a good 15 minutes and even backed off the exhaust by a quarter turn so that it could turn freely.
Turned the engine over by hand so that I could adjust the rear cylinder and the front exhaust pushrod bent again.
I'm not a newbie to wrenching and am a certified auto mechanic. I'm tempted to just back off further on the exhaust valve adjustment, but somethin had to have caused the problem to begin with. I may be just havin a brain fart, but I can't keep buying pushrods. Anybody have any ideas on where I may have gone astray?

 

Sounds to me like a cam timming issue. Did you install that cam while it was apart or was the cam already in it?

Re'

 

Since this is one of those kinds of problems, back to basics. Just trying to help here now. Sometime it's the little thing gets by.

How are you determing the front cyl., or rear is on the base curve of the approiate cam?

With spark plugs out, shortened pushrods, got to roll the engine to TDC on compression stroke.

Gotta make sure you are on the compression stroke not the exhaust stroke. With loose pushrods can't hold your finger over the plug hole.

I watch the pushrods go up and down, all shortened, till I make sure both are down. Cam is in the valves closed, or close to TDC, for that cyl. Check the piston thru the spark plug hole with a soda straw. Move the engine gently back and forth till just the toppest.

That ought to be the place. Time to adjust.

Just my way. Just one way

 

Not trying to be a wise guy, but did you let the lifters bleed down, prior to rotating the engine?
Scott

 

After pulling them all back out I got a set of Screamin Eagle Easy Install adjustables and put those in. Adjusted them according to instructions, let the lifters bleed down for a good 15 minutes and even backed off the exhaust by a quarter turn so that it could turn freely.

I'm thinking yes.

Re'

 

That's weird. I would look at you cam timing again as mentioned by Re. Pistons hitting the valve at a time it shouldn't considering you went with adiquate bleed down.
Ron

 

Im going with Old Gunny and be sure you are on the base circle of the cam. You could be 180 degrees out on your adjustments.???

 

But if he was not on the base circle of the cam, that would just cause the pushrods to get loose when you turned the engine over. You would LOOSE lift, not gain it. No chance of the valves hitting the pistons and bending pushrods.

Hey FLHRIDER, you started this thread, where are you.

Re'

 

Yes, thats right.

Well much as it seems to be, there is no majec, so it is back to basics.

 

Hey all. Thanks for the ideas. It was an existing cam, so no issue there. Gunny, your way is the same as mine.
My biggest concern was that the valve timing could have somehow changed when I pulled the jugs. I'll try reassembling and check lift on the exhaust lobes of the cam. If the lift and the timing seem right then I'll try readjusting the pufhrods.
Thanks.