All,
   So for those of you that haven't had chance to ripe apart you engine, here's what it looks like when you split the crankcase.


for bigger pic see: http://www.users.fast.net/~tommack/photos/100_1946.JPG

To the left is the transmission, to the right is the crankshaft, and far right behind the gear is the counter balance.  Not very much inside.

-----------------------------------
Reason I have is apart is:


also see: http://www.users.fast.net/~tommack/photos/100_1948.JPG


Notice the shape of the aluminum, yes it actaully flaked off.  I'm going thru and doing an ultra clean to make sure there's no flakes around.  Got the bike as a rolling frame (very clean 2001 frame). The previous owner was not mechaniclly inclined.  The amount of cleaning I'm doing would have cost of ton of Labor fee's.   Was not cost effective for him to rebuild.




also see: http://www.users.fast.net/~tommack/photos/100_1950.JPG


also see: http://www.users.fast.net/~tommack/photos/100_1951.JPG

Here's a shot of the Oversizeed piston next to the old one.  Yes, your eyes aren't playing tricks, the old piston is bent.

What caused that?

Previous owner said he was driving down the interstate on his way home from work (evening shift so it was 11 PM'ish).  He said it lost power as if it ran out of gas, but he knew it was almost full.  He switched to reserve and it picked up for a second or two then died again.  He said it would turn over but not fire.  He took it to a repair shop and they said he needed a new engine.

What we found:
- Oil in the little  recesses here and there was black, so it makes me think he missed an oil change.

- Upon cleaning the embedded aluminum from the cylinder sleeve, the machinist said the cylinder was a hair undersized.  Tight cylinder to start with doesn't help a air cooled, factory leaned out bike.  Note: the machinist is a friend and is doing the labor free.  He has a "better idea" for the head cap plug too, but will report on that once I know it works.  

- I don't know if there was oil in the gas because the oil was drained and the engine in pieces when I picked up the bike.   Couldn't smell gas in what was there, but the engine sat in a box over the winter.

- Gas in the oil, I take it your thought line is the petcock,...  Well there was gas in the tank, the carb was off and no tell tail signs of gas on the fuel petcock fittings when we got home from the 6 hr drive picking it up. But, I still have to check that over.  I was thinking of temporarily putting clear hose on the vacuum line to watch for fuel movement after I get the bike together.  

- I'm now waiting on parts.  The O.S. piston "kit" didn't come with a wrist pin or circlips, so I ran down to the stealer (oops dealer) and ordered them. The parts guys also thought the kit would have included them. I should have asked the forum. Well, I called to day and they said the order only went in yesterday, not last Thrusday when I ordered them.   And, the RonAyers order of gaskets, Cam chain (the engine is apart,has 10K miles, why not) and oil filter is still showing as waitng fullment (order went in a 7 days ago).  

Indeed - interesting pic and a lot of space in there.  Thanks for posting.  Me, I'd be worried about reusing that connecting rod after bending a piston.

Connecting ROD, yes, there is still the question of the connecting rod.  

On a good note, the rod is steel , piston aluminum.  The rod is also futher away from the heat. But......

I'm now waiting for the wrist pin to check.

Since y9ou are about to stick a new cam chain in, maybe you would like to go for the Cryo treatment on it? I have done a bit of looking into it & if I remember right, its dang cheap.

Yes, cam journal was bad.  Replacement head assy from salvage yard (w/ guarantee) $200.

Rockin_John wrote on 12/31/69 at 16:00:07:



Yes there are pictures of the inside ( made them myself)
Second: when the engine is on it's LH side, tap the shafts with a non-malet hammer to keep them in the LH crankcase half, no problem at all.