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In normal operation the pushrod rotates. It also flexes under vibration and load. As it rotates and flexes it contacts the hard plastic insert that it passes through in the pushrod guide plate. It takes a while but the insert burnishes the rod so thin in that spot, it breaks. The process also changes the length of the rod and therefore the valve lash, so I always readjust the intake valve (or the one with the compression release) as soon as the starter starts to stall into the compression stroke on startup. Or at every oil change or tune up whichever come first. When I do, I back the rocker nut off far enough to remove the pushrod and inspect it. If its starting to wear a dish shape into the rod I flip the rod end for end and reinstall it. It can start wearing on the other end until it goes dish shaped then I replace it.

In closing just one other possiblity that usually bends the rod rather than break it is old varnished fuel stuck the valve in its guide and the rod gave way on start up or soon after.

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Q: Why did the aluminum intake pushrod brake on a 17.5 Briggs and stratton eng?
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