R100GS Tappet Replacement

[Tone5]

When doing the valve clearances on my R100GS I've succeeded in stripping the thread of a tappet and locknut (though I suspect the threads were fatigued before I started working on it).
Anyway, I've managed to get the stripped nut off, but how do I remove the tappet to replace it? Unscrewing the tappet from the rocker arm does not seem to work because the pushrod is in the way. I've got the engine at TDC. There does not seem to be enough free movement of the pushrod to push it aside to get the tappet out. Do I have to remove the whole rocker assembly?... I hope not!
Thanks

 

[Roger Chatterton]

I had similar problem which I solved by loosening the cylinder head nuts in both rockers, but loosened the offending one’s almost all the way, and raised the rocker. Just about enough space, in mine, to remove the tapper and replace with a new one.
Was tight though.
Other way is just to remove the whole assembly, but do it carefully so that it doesn’t all come apart !


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[Smug]

If you lever the valve down you should have enough clearance to get it out.

 

[DrFarkoff]

Do I have to remove the whole rocker assembly?... I hope not!

Just undo the cylinder nuts on the rocker posts that you need to work on BUT have a decent torque wrench to hand before you try to don them up again and Err to the lower values of torque

If you try to horse the cylinder head nuts home you can pull threads in the block HENCE good torque wrench and lower values!

If you lever the valve down you should have enough clearance to get it out.

Engine is at TDC

If you decide to try Smugs method? Before you try to pressure the valve into the combustion chamber to give clearance

Move the piston down the bore an inch and a half on the cylinder you are working on so you can;t ding the piston and possibly bend the valve !

 

[Tone5]

Thanks for your words of wisdom. I'll try the Smugs method sometime over the weekend and let you know how I get on.
Cheers

 

[Steptoe]

FFS, just undo the two nuts on the rocker pedestal, lift it off and remove the tappet.