Valve Rocker Arm 14441-Z0J-000

Well the Pressure washer had been stored for about a year. In preparation for storage I had done all requirements per the manual. Remove all fuel from the tank and carb, change the oil, put a spoon full of Honda oil in the spark plug hole and pull the cord a few times. So all is great right? Wrong! When I went to pull the cord to start it jerked my arm real hard I let go of the rope and the starter rope and grip got sucked back into the assembly slapping the tar out of the back of my leg. Another words the engine kicked back. As any man would do I went ahead and pulled on it like a dummy two more times before I convinced myself something was wrong with the motor.
When I start my pull start motor I try to start them at Top Dead Center knowing this and experiencing the kick back almost immediately after pulling the cord and feeling the high level of tension getting there I immediately suspected a stuck exhaust valve.
I took the 4 valve cover bolts off and carefully pulled the glued on valve cover off to see that the rocker arm for the exhaust valve had been split. When the rocker arm was putting force on the valve and the valve didn't move the rocker arm broke. Fortunately the exhaust valve wasn't so stuck that 2 taps with a dead blow hammer freed it right up. Replaced the rocker arm and set the valve clearance to specifications and verified the intake valve clearance as well (clearances was set to 0.15mm intake and 0.20mm exhaust).
A few things that I took note of since this was the first time I have worked on the this motor. Most of the motor does not use gaskets it calls for Honda Bond 4. I Permatex Ultra Grey RTV. You could also use Yamabond 4, but the Permatex is cheaper and more readily available.
This motor does not have a removable cylinder head. If you have a ton of hours on your motor maybe 100, 200, maybe 500. You may as well tear the motor completely down anyways and replace the timing belt clean the cylinder head (Which you have to do by going in through the bottom of the cylinder, and inspecting the parts of the bottom end). I didn't even consider doing all that because my motor had less than 50 hours on it.
My Lessons learned from this is that in addition to what the manual says to do for long term storage I will also be taking off the muffler and carb to have access to the intake and exhaust ports. While cycling the motor with the starter rope I will spray some PB Blaster on the valve stems as additional lubricant to the motor oil that already got poured into the cylinder, and then cycling the starter rope to store the piston at TDC(top dead center) to trap out any moisture that could possible freeze up the valves.
I know this was lengthy, but if you took the time to read all that I wrote I hope that it'll help you in the future with your equipment repairs.

Thanks,
James

Remove cracked/ broken rocker arm replaced with new one and set to proper adjustment.

Remove valve cover. Remove Ex valve rocker. Replace Ex valve Rocker. Same for In Valve Rocker even though it was not damaged. Turn engine to timing marks, piston TDC.
Adjust lash at intake and exhaust rockers. Replace valve cover.

Engine would not start, found stuck exhaust valve and broken rocker arm. Was then able to start engine, but then had knocking noise. Tore down engine and found play in connecting rod assembly where it connected to crankshaft. Replaced connecting rod assembly, new rings, honed out cylinder and replaced rocker arm. Cleaned all parts.

After reassembly, did not have any compression, found adjustment out on the rocker arms, was keeping exhaust valve open a little, not allowing compression to build up. Adjusted, then after two or three pulls, engine started.

With the timing belt, it is important to make sure that is reassembled correctly to have valves timed properly. Found a video on youtube that explained how to do that.

Unit would not run and backfired through carburetor. Removed valve cover and found broken exhaust rocker arm. Replaced both rocker arms. Performed valve lash adjustment. Reinstalled valve cover and installed new air filter. Unit started up on second pull and took a minute to start running normally.

I removed the Honda CVS160 engine from the pressure washer base after disconnecting the pump. After removing the rocker/cam cover and discovering the broken exhaust rocker arm and damage to the camshaft I surmised that the timing belt had slipped and caused the damage. I then split the upper and lower portion of the engine case and pulled out the defective timing belt. I had to remove a crankshaft coupling that was keyed to the crankshaft prior to taking the case apart. I installed the new timing belt and reassembled the lower case. I then replaced both rockers and the new camshaft/pulley and replaced the cam cover with new sealer. The engine started and ran perfectly showing that no damage had been done to the valves or piston.

Removed valve cover. Only 4 bolts
Removed lifter pins ( held in by the cover)
Replaced lifters with new parts and set lash.
Replaced cam pulley
Put sealant on back side on cover. Installed cover by tightening 4 bolts
Let sealant set up over night.
Added oil and gas....... Engine started on first pull!

Removed valve cover evaluating stalling motor and tapping noise.
Found rocker arm cracked
Placed order online
Received new parts removed old parts
Adjusted exhaust/intake to proper position
Replaced valve cover
Topped off motor oil to proper level
Started motor, adjusted carburetor lean
Happy customer

Replaced cracked rocker arm and retainer pin.
Removed valve cover, rocker arm, and pin - replaced and adjusted.

1. Remove the starting coil.
2. Remove the spark plug.
3. Remove the exhaust guard.
4. Remove the valve cover.
5. Clean the gasket surfaces.
6. Install the new rocker arm.
7. Set the rocker arm gap.
8. Put it back together.