What the hell happened !!!!
Firstly I DO think your best bet is to start with another engine…but maybe take you time and look for the correct engine otherwise you’ll add to your misery….
OK so know you know the hard way…..
Your old engine is f*****ed its impossible to hone an engine to take a oversized piston ring, it needs to be machined and all over-sizing needs to be done as a kit, eg cylinder, piston and ring.. the cam / timing chain is imperative its correct… Did you compare the rear head to the front, establishing too much was removed ? how did you decide how much to take off the end of the valve ?
To build a reliable engine, you just can not machine parts to fit… any of the factors you state would have a fatal effect on your engine … including stretched timing chain, worn timing chain tensioners… in my humble opinion a rebuild, should have been a re-bore, new pistons, rings, chain and tensioners, maybe crank and big end bearings… then ask the question does the head also need doing, do the valves sit properly is the cam worn …etc
If not then STOP and work backwards, something is very wrong,
Conclusion, wrong timing, wrong chain adjustment, valves and valve adjustment @ 4000 rpm beat the hell out of the valve, valve breaks and drops into the engine destroying it…
Expensive lesson, but the new engine, you’ll regularly maintain and look after – won’t you ?
This is all basic automotive engineering, I’m surprised a local bike shop couldn’t help an Overland Traveler out …
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