A maule M5-at in cruise at 4000 ft experienced rough engine operation and returned to departure airport. Found #4 cylinder had ingested a failed valve.

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Attributes
ACN	659104
Time
Date	200505
Local Time Of Day	0601 To 1200
Place
Locale Reference	airport : zzz.airport
State Reference	US
Altitude	agl single value : 4000
Environment
Flight Conditions	VMC
Light	Daylight
Aircraft 1
Operator	general aviation : personal
Make Model Name	M-5
Operating Under FAR Part	Part 91
Flight Phase	cruise : level
Flight Plan	VFR
Person 1
Affiliation	other
Function	flight crew : single pilot
Qualification	pilot : commercial pilot : instrument pilot : multi engine
Experience	flight time last 90 days : 50 flight time total : 600 flight time type : 300
ASRS Report	659104
Events
Anomaly	aircraft equipment problem : critical
Independent Detector	aircraft equipment other aircraft equipment : engine tech other flight crewa
Resolutory Action	flight crew : overcame equipment problem other
Consequence	other other
Supplementary
Problem Areas	Aircraft
Primary Problem	Aircraft

Narrative:

Rough engine. Couldn't rectify. Returned and landed. 10-15 mins from airport; #4 valve sucked. O-540 lycoming -- broke off stem/head; 7/16 stem -- 2 parts valve found in muffler. Engine was overhauled 1000 hours ago. I'm doing complete overhaul now.

Original NASA ASRS Text

Title: A MAULE M5-AT IN CRUISE AT 4000 FT EXPERIENCED ROUGH ENG OP AND RETURNED TO DEP ARPT. FOUND #4 CYLINDER HAD INGESTED A FAILED VALVE.

Narrative: ROUGH ENG. COULDN'T RECTIFY. RETURNED AND LANDED. 10-15 MINS FROM ARPT; #4 VALVE SUCKED. O-540 LYCOMING -- BROKE OFF STEM/HEAD; 7/16 STEM -- 2 PARTS VALVE FOUND IN MUFFLER. ENG WAS OVERHAULED 1000 HRS AGO. I'M DOING COMPLETE OVERHAUL NOW.

Data retrieved from NASA's ASRS site as of January 2009 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.