Complete Bike Rebuild?? Worth it?

As others have suggested, do a compression test first. If you find an issue then rebuild the engine, but only if. Depending on the mileage internal things that might need attention would be any rubber items, cam chain guides, valve guide seals. Otherwise these engines are pretty tough and reliable if not abused.
As for the frame and your PC concerns I fully understand what salt air will do. I'm currently working on a bike for a friend from the Savannah GA area and almost all the chrome parts are trash and I'm either replacing them or stripping and coating them.
 
As others have suggested, do a compression test first. If you find an issue then rebuild the engine, but only if. Depending on the mileage internal things that might need attention would be any rubber items, cam chain guides, valve guide seals. Otherwise these engines are pretty tough and reliable if not abused.
As for the frame and your PC concerns I fully understand what salt air will do. I'm currently working on a bike for a friend from the Savannah GA area and almost all the chrome parts are trash and I'm either replacing them or stripping and coating them.
Im from sav! I just ran compression… bad news right side got right around 100psi, left side got like 5psi… ill be running a leakdown test pater today, but im assuming Ill need to rebuild right?
 

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but im assuming Ill need to rebuild right?
Nope, not yet. Did you have the carb butterflies wide open while you tested? They need to be.
Did you squirt a little oil down the plug hole, kick the engine through a couple times and repeat the test?
 
Nope, not yet. Did you have the carb butterflies wide open while you tested? They need to be.
Did you squirt a little oil down the plug hole, kick the engine through a couple times and repeat the test?
No, ill google the carb butterflies, and will normal engine oil work/ i have rotella 15w40 which seems to be recommended here
 
No, ill google the carb butterflies, and will normal engine oil work/ i have rotella 15w40 which seems to be recommended here
So put some oil on comp test tip, held throttle open to open the butterfly valves, still 0 :/

@Jim thanks for the advice by the way, you @gggary and @5twins are such a wealth of knowledge and welcoming to us new guys ive seen you all on at least 100 posts each and its always been good information (although admittedly i dont know half of what youre saying most the time haha)
 
So put some oil on comp test tip, held throttle open to open the butterfly valves, still 0 :/
You need the oil in the cycliders to help seal the rings.... at least 'til you can run it and check compression after. And yes, any motor oil will work. Just a squirt or two from an oil can. Don't go overboard.

RE: the 0psi side.... check and make sure a valve isn't stuck open. No pressure buildup kinda points that way. Pull the valve covers and check/set your valve clearances.
 
So update to the comp test, right side got up to 105 with butterflys open, still 0 on left side. Reading through bushys original build of this, i see something about the cam bearings moving and gaskets potentially exaggerating the movt. The gasket i built for this is pretty thick (its for a pretty heavy duty diesel boat engine) and im wondering if that could be enough to cause blowby (blowback)?
 

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You need the oil in the cycliders to help seal the rings.... at least 'til you can run it and check compression after. And yes, any motor oil will work. Just a squirt or two from an oil can. Don't go overboard.

RE: the 0psi side.... check and make sure a valve isn't stuck open. No pressure buildup kinda points that way. Pull the valve covers and check/set your valve clearances.
Alright 3rd times a charm hopefully, if not then ill pull valve covers and check
 
Welp the oil worked a bit, the compression on left side got up to a whopping 15psi! Pulling valve covers in a bit to check them.
 
Got the valve cover off front left side, gasket has disappeared so ill order new orings seems like it does not want to move and smells like burnt oil in there, but ive got to put her away for now and will report back probably sunday with more information. Thanks everybody
 

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Got the valve cover off front left side, gasket has disappeared so ill order new orings seems like it does not want to move and smells like burnt oil in there, but ive got to put her away for now and will report back probably sunday with more information. Thanks everybody
Tested this valve because i didnt want to walk away with the job almost down and it seems like its moving fine
 
OK moving is good but is there play so it actually can move to the endpoint both valves
and closing
Intake and Exhaust please search the net you can find info how the play is set
Feeler gauge or feeling by hand that is free at some point turning the motor
Left side
 
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