well............ it's a rather embarassing story

but i'll post it here in public so you can all have a good laugh

ound:
It all started when I overhauled my engine before fitting it back in the Sportster. As the engine ran fine in the old BMW I decided not to do a full overhaul of the cylinder head but I did replace the camshaft, rockers and rocker shafts from another head I picked up on ebay.
When I set up the valve clearances, I looked up the manual and it said 0.25mm. I then picked up my feeler gauges and picked the one marked 025 and set up each valve in the spcified order. The engine has ran fine since but has always sounded a but noisey (which I think I may have mentioned on this forum?)
Anyway, it was only after listening to Robin's engine last week (his car is looking great and just about ready for SVA next week, good luck, Robin) that I realsed that there is something definately wrong with my engine. On the way back from Robin's place my mind was running wild with thoughts of worn bearings, knackered camshaft, burnt valves, etc when suddenly i had a thought... (yes, you've probaly guessed by now...)... supposing my feeler gauges were old imperial ones and 025 was actually 0.025". For those of you too young to know, we used to use feet and inches and feeler blades were in thousandths of an inch!

Well, 0.025" is in fact 0.635mm so my valve clearances were set to 0.635mm instead of 0.25mm
It just shows you how tolerant that M20 engine is in that it'll happily run with such large clearances!! No wonder it sounded like a bloody Singer sewing machine
OK, that's enough, you can all stop laughing now...........