pulled the head cover, cams, and head , stator cover clutch cover....

looked over the valves under visual inspection they look pretty good i am thinking may have dodged a big bullet by deciding to ripped this bike down no and not waiting any longer....
now its time to crack the case and hope all the bearing journals are in great shape.... but things are looking like i got to it early

 

started pulling the clutch plates and come to find out i didn't have the socket i needed to remove the basket... so i run out get the tool come back and set it aside.
went under close examination of the cluch plates..
i ended up finding the last plate shattered and found a cracked clutch basket ....UH OH... on the list of needed gear

 

Spent a little more time today on the engine... removed the oil pan and and oils pick up... when i pulled the oil pickup i heard a clank... the wth thought ran through my head so i shook it out and out drops a piece of aluminum about the size of a quarter.....

next thought oh SH** where the hell did this come from so i start searching found piston with free play and it had broken a section below the rings so while i wait on my clutch tool i am going to flip the block and get that piston out of there...

so interesting twist around the bend.... but this answers alot of noise issues i had experienced....

so i will have to see if the cyclinder is still in spec and verify crank condition...

so it is turned into a little of a nail biter.... but nothing that hasn't ran through my mind as a possibility....

 

Good luck on your rebuild. Thanks for sharing. Will be following your progress.

 

Please keep documenting pics and I do on this... Best of luck with it.

 

still waiting on my clutch tool ... might search local or talk to my brother see if he has what i need. been reading about how to make what i need but we will see..... at this point i have most the answers that i needed... so i will be at a stand still till i get my new crank and pistons in....

i will be starting on the frame in the mean time..

i went out and worked on the bike for a while this evening and dropped 1st,2nd,3rd pistons out... see what the # 2 piston and cylinder looked like. this is what i found






here is what was left of the bearing little crappy of a picture but it gets the
point accross

 

check the clearance specs of the cylinders and it looks good but
here is a comparison between the 3 cyclinders you can see the major difference in the bearing wear and damage caused to the crank.

cylinder one


cylinder two you can see the damage at a glance


cylinder three

 

so as it stands now in order to get this engine running properly.. i need to order new crank and new pistons the get the proper bearing once i get them in so the down time on the engine will be obvious... i will be checking the transmission out in a greater detail.. but out of surprise the gear dogs and gears look pretty good but i will have measurements to take to verify.

so in the mean time in the wait for tools and replacement parts.. i will be cleaning engine and frame parts up....

 

any idea on how you think it happened? the top ring looks a little stuck as maybe it started slapping and chipped the skirt off,
and then the bearing followed. is the connecting rod still in good shape? also are you doing cast or forged? i would go cast pistons.

 

Great thread. Good luck on the rebuild! Keep us updated!