1984 Honda XL600r - Engine Rebuild (Slideshow)

The XL600 was leaking a little oil from the crankcase and planned to only replace the crank case gasket. The engine had other plans.
The bad:
Realized I used a XR600 head gasket instead of an XL gasket on the first rebuild, XRs have a 97mm bore.
Head warped .004"
Bore is glazed and tapered
Rings were tired and near service limit
Thread insert on cylinder backed out and did not allow head to mate properly, the laminated head gasket is very forgiving
Cam chain lifter is worn out
Broken clutch dowel Piece
Damaged left crank case
Clutch dowel pocket feature in stator cover wallered out
The good:
Fixed all oil leaks
Installed new oil seals, rubber orings, and paper gaskets
Installed new bottom end bearings
Replaced left crankcase half, found a used XR86 stator cover in better shape
Replaced clutch lifter piece, push rod, and used longer clutch lifter lever
Replaced cam chain lifter
Decked head flat, performed valve service, bead blasted head
Installed oem 0.5mm rings, needed a bit of sanding and grinding to make them work
Honed the bore, shop said to reuse the 0.5 piston
Camshaft and rockers were fine despite heat warpage to the head
It runs
Music: Cascade Nights - Hello Meteor