DBM,
We have longer roads here on the mainland than you guys. I don't think you have any interstates on the islands.

ALL of the holes were plugged!

I had a history of 2 maybe 3 oz. per thousand miles, and about 4 or 5 thousand miles ago it started drinking oil. I am hoping it's cause thats when the all holes clogged. I am about finished puting it back together an should have it running tommorow.

As far as I know Dave and I are the only ones running BOTH Kaw pulleys 25/65. They drop the final drive to 2.6, with a 140-90 15 rear tire that gives me about 3400 rpm at 60, compared to 4100. So crusing at 60-65 is easy on the motor. I ride quite easy in my old age and seldom go over 4000 rpm or 65 on a I.

I am using the dual piston caliper and larger disc (290mm) from a SV650. With a braided SS brake line, and a 16" front rim. 3 fingers WILL lock-up the front wheel at 30mph, I haven't really tried faster than that, but when I need to stop quick I can.
Mounting the caliper is easy, tape a piece of single strand insulated 14ga electric wire to the outside of the disc, that will be your clearance. Place the caliper where you want it,and make a template for your mount out of cardboard. Transfer the template to steel, I used 3/16", cut it out and drill some holes,,,,TA DAAA!

You were right a couple years back saying that without the pawl on the chain tensioner the cam would jump all over messing up the timing. I think more so on the bench than when running at speed thou. But I ran 40k miles with the movement growing from 1.5mm to 6.5mm and never noticed a big change in the way it ran. (other than the oil useage) I am going to check it more often now and try to keep it at less than 3mm.

I am still hoping to ride out to see you, as soon as they build a bridge.

badwolf

Badwolf:

Congratulations on the mileage - it is nice that you ride your bike a lot!

Your oil drain hole issue has me wondering?  It seems odd the drain holes would plug up - but you did not indicate the ring grooves were filled with carbon.  In the old days I expected to see old engines have the rings cemented in place by the build up of carbon in the ring grooves.

From the lack of wear on the engine parts it appears the oil is doing a good job of lubricating - but for some reason it isn't cleaning the piston holes adequately.

In the risk of starting an oil war - what type of oil and what change interval are you using?  Does the inside of your engine have dark staining or build up of sludge on the head or other surfaces?

Were the holes plugged up all the way around the piston - or only on the exhaust side?

Are you running an oil cooler?

The holes were pluged all around, the rings had crap around and under them, but were not frozen. You could move them around and expanded by themselves when I removed the cylnder.
The top of the piston was covered with a THICK layer of carbon along with the head.
No oil cooler, and I have always run Rotella T4 dino.

Rode it today, started right up, idled nice and ran fine 25 miles. Put a new (to me) Dyna muffler on, much quieter than the worn-out one I had been running. Feels like this one is more restrictive thou, have to run a couple tanks thru it and check the mileage.....AND OIL.