Is everyone else able to see the pictures?

Upon having time to think this out, I think I will try to JB weld the broken piece back in place. Past experience tells me it should hold and may get me back going with this head.

 

No pics showing.

 

Hmm. I see them on my end. I went and made them public pictures on my flickr account, does that make them visible?

 

pictures, yes.
If you use special lube on the bolts, I believe you need to drop the torque values.
Did you do that after the noise video?
I would turn the motor upside down and see what falls out!

 

Yes, I cracked the head around the bolt after the video.

I've got the clutch side of the engine off so I was able to retrieve the broken piece. I think I'm going to JB weld it back in place and then just seat that bolt lightly, I cannot imagine its that significant as long as the four main larger bolts are in and torqued.

 

I'm back. I put the bike back together last time and its pretty much set since. The good news is that after cleaning the carb and a couple of new jets that the starting and idle issues have been resolved. The bad news is there is still a noise in the motor. As someone recommended I bought a mechanics stethoscope and listened to the engine while running. The noise definitely appears to be coming from the piston/cylinder, so I spent Sunday afternoon pulling to top end back off the bike. Once I got to the cylinder and piston I started measuring everything and the piston and rings all checked out, but the cylinder is out of spec. The inside diameter of the cylinder measures 72.08mm and the manual says anything over 72.07mm is out of spec and should be replaced. It doesn't seem .05mm would make that much difference, but I will find out when I get the new cylinder. I think I'm going to try the AHL 299 that a couple other members have used now.

 

0.05mm is just short of 0.002" which is probably about the recommended piston clearance, so yes it is a lot. I will say the 299 makes sense since the cost is relatively low and you have it apart anyway. You want to go to ebay to buy one if you want it fast, make sure how fast thought. From Amazon it took 35 days for mine to show up on the slow boat from China. Someone got one from ebay in a matter of a few days. Read the delivery time for sure.