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I have also used the Caswell epoxy sealer. I've done two tanks now with good results. Both tanks had leaks so they needed either a sealer or some metal work done. Wanting the paint on each to remain intact, I chose sealer. One thing I don't like about it is I have no idea what I would do...

I am curious as to why you chose a twin shock swingarm instead of a swingarm already setup for mono shock. (?) Ken

Back in the early '90s I rode an '82 XV750 without a front fender for a year or two. It was my only transportation so it was in all weather. I would lean my upper body/head one way or the other to stay out of most of the spray. As the speed increased, say 45+ , it was being dispersed more...

PM sent. Ken

Rings normally pass both oil and combustion gasses in manageable amounts. Head gaskets do not. How does the head gasket readily leak oil inward enough to foul the plug without also leaking highly pressurized(1000+ psi) combustion gasses outward? Ken

There is one thing I'm not understanding on this "it leaks oil into the combustion chamber from the cam chain tunnel" idea. How does it leak oil into the chamber under the relatively low pressure differential during the intake stroke but does not leak out combustion gasses on compression/power...

Since it seems to occur despite completely different cylinder/piston/ring sets one would expect the issue to be either above or below that. You mention you have new valve seals but no mention of what the guides/valve stems are like. If a guide or stem is worn enough(or too far out of spec...

XSNate may be on to something here. Look up Rekluse. The XS clutch is not going to allow for the low speed stuff like one of these does. I can readily imagine that a rider who learned on a bike with a Rekluse would be in for a few stalls when transitioning to riding a regular clutch...