MB

Presume changing the tensioner cured the top end rattle?

It may just have been some looseness that caused the initial shell wear.... or some oil starve as you say - it wouldnt take much time to cause some damage!

You could then say that it caused some play lower down and allowed some leakage. Hence its best to check bores dimensionally.

MB

cdelena

There are actually a couple of methods to test for guide wear... one is actually called the 'wobble method' where the movement is measured. Or the ID of the guide can be compared to the OD of the stem. The manual has details.

Asura

There is an acceptable tolerance range for valve guides outlined in the Helm manual. You need to remove each valve and slide it out of the guide 10mm. Be careful as the retainer keepers will want to fly across the room. Measure the guide to stem clearance by wobbling the valve.

If the measurement is over the service limit, re-check with a new valve. If the clearance is still over the limit with a new valve you have to check the clearance inside the guide with a gauge.
Subtract the Outer Diameter of the valve stem from the Inner Diameter of the valve guide. The delta has to be with in the service limit or the guide has to be replaced.
Not a joyful procedure. Rather tedious, but not impossible.

s2kVABeachCruiser

Since the motor is so far torn apart, I'd replace nearly everything I could...piston rings, any and all bearings and seals, and have the head totally reconditioned as well. That should certainly fix any oil consumption problem assuming the block, cylinder bores, etc are okay. Just my thought...

Slows2k

The Cam journals look fine, as is the carbon on the backs of the valves. A cylinder leakdown would have been advisable before taking it apart.

Unless Honda UK is doing something different than AHM, your car has the incorrect PLM oil filter, instead of the larger PCX model.

Asura

Check to make sure the crank, journals and block are true as well.

Pie_n_Chips

Mark - replacing the cam chain tensioner did didly squat for the rattle

Part number of the installed filter is 15400RBAF01 apprantly these supperceeds the older PCX model ????

univex

I had a similar problem with my MY01 S a few years back, turned out that there was a problem with the valve stem seals. The dealer originally tried to keep it quiet, but after a long conversation with Honda technical i discovered that there were a certain number of vehicles produced during 2001 that were fitted with incorrect seals. The car developed problems after racking up around 50K, and just got worse. I think the dealer was trying to fob me off, but the car was sorted out after 6 weeks of driving around in the dealers S demo.

Pie_n_Chips

Latest update here

Basically it's the warranty company cop out letter