Trash Stator/Alternator or reusable?

Yes looks fine to me too. I would rebuild it if it was my bike.

You should replace the cam chain too since you have the cases split if all the checks k-moe advised you to do are fine.

 

I briefly looked over the bearing. No damage so far. On the top of the piston bores there’s a ring of rust maybe a 1/4 from the top. I dunno if a hone would get rid of it or just fine W/D sandpaper

 

That is the space between your top piston ring and the top of your cylinder where the rings don't contact. Try a stout plastic scraper first, don't use a hone on it. My cylinders were the same. Here is a photograph from my engine rebuild you are looking for cross hatching the crossed scoring you see on my cylinder wall. You can see the line where the top piston ring stops, the light brown at the top of the cylinder. The cross hatching is to keep oil on the cylinder to lubricate the cylinders and piston rings.

 

Ok sounds good

 

Is this just rust build up or was there some sort of gasket around these bolts? It was just falling off while splitting the engine. (Green arrows)

 

There was tubing fitted at the factory to protect the front studs your arrows are at. Studs are visible looking at the front of the engine through the cooling fins when the cylinders are on. I think the reason was that the front studs were exposed to road dirt and can corrode. I had problems getting the cylinders off my engine because of it. I decided to rebuild it without new tubing. You should be able to clean the dirt off with some steel wool. A lot of the corrosion and dirt fell into my engine but I was splitting the cases anyway so it didn't matter. From your photograph it looks like there is still some tubing on the stud next to the cam chain.

 

The tubing you mentioned is barely holding on so ill prob just pull it off. I should prob take closer pictures for you guys to show how crappy it looked. Thanks again.

 

Yes remove it. You can get new tubing and other parts from Chacal on info@xj4ever for the rebuild if you wish.

 

Yea me and Chacal have been in contact since i got the bike and did the carbs

 

Here is Mezzmo's engine rebuild video, will be useful for you for reassembly.

 

Ive watched Mezzmo's engine overhaul a bunch already. Theyre my go to source when i cant find it in the book.

 

Ok great. When you split the cases heat up the two bolts before removing them that secure the starter chain guide to soften the factory threadlock. The bolts can break otherwise.

 

the upper bolt was so corroded that the head just fell off with minimal force. had to drill it out and gonna re-thread it. other two came out easily

 

Good you got them out, I forgot you have already split the cases lol.

 

Whats up gents. Been MIA for a bit. Too cold out to be cleaning in a unheated garage. Slowly bringing in parts to clean in the house. I didnt give up just too damn cold,

 

you can use 9mm heatshrink tubing ,on the cylinder bolts, not the 2 rh ones though, they're the oil galleries

 

Thanks for the heads up

 

Never ending cleaning

 

what up guys? I have a question about the connecting rod bolts/nuts when I'm checking clearances for the bearings and journals. I know I have to replace them once the rods are split but do I have to replace them again after I use plastigauge?

 

use the old bolts and nuts for the plasti check then the new ones for final assembly.

and no if you use the new ones there will not have been any stress on them besides the torque