Valve Clearance Set

Valve clearance adjusted. Intake side was OK. Exhaust side was too tight. Opened up to 0.007".

Flywheel Key Not Broken

I did find a chunk of the aluminum boss that broke off from the idler gear. Still worth pulling the flywheel.

Homemade Puller. Thanks Eric.

Key wasn't sheared off like I suspected. Now I'm stumped as to why the timing is slightly off. Oh well, we'll see if it runs and then worry about it.

 New stainless studs for the exhaust, cut from M6 SS threaded rod. New exhaust gasket too.

New gaskets and wire brushed the carbon out.

Timing Off Slightly

With the "T" lined up in the hole on the cover, the line on the cam chain sprocket won't line up with the upper mark. It's either on one side or the other. Somehow the timing is off just a bit. As far as I can tell, the flywheel must not be in the correct position, which means that the key must be broken. I guess I will pull the flywheel and confirm.

Rear Axle Removal - Haynes Manual is Wrong

I should have posted this earlier (before the diff rebuild section), but just so you know, the Haynes manual is wrong about which way to remove the rear axle. (I found out the hard way). You should be tapping on the brake side (RH side) and the axle will come out toward the LH side of the bike. I wonder how many people have bashed the crap out of their axles (and ruined the threads in the process), trying to take the axle out the wrong way.

New Top End Gaskets

For some reason, these pictures keep uploading in the wrong order. Here it is going back together.

Cam chain

Cam chain tensioner

The chain guide will come out through the opening first, then the head can come off without having to remove the engine from the frame.

Put a piece of wire on the cam chain so that you can pull it back out easily.

All cleaned up.

The exhaust studs broke off when removing the nuts. We tried welding nuts onto the studs and then heating it up with a torch, but they still wouldn't come out. They had to be chopped off, drilled out & re-tapped. Thanks for the help Eric!