TOPIC:

wrote:

At this point nothing adds up....
According to all test performed and where oil  is observed oil flow is not the problem
1  oil is causing pressure gauge to show pressure at oil transfer  elbow
2 oil pressure if not allowed to flow from pump has cause some to have oil filter cover blowing seal or warping  ( breaking ) cover  at oil pan   ( Not reported here )
3 signs of oil to top of block  shows flow to head 
4 air blown thru head passages  shows no restriction 
Im at a loss for what is wrong  , So     start over 

Crank motor over to see unrestricted flow with head off to top of block 
If poor flow   pull  transfer elbow off from behind motor to check for plug from oil  cooler used priorly or a restriction in the area. This is biggest change you made by deleting the cooler from system
Next pull block and look for  restricted  oil supply from ports coming off cases and look for silicon in stud bores from prior assembly of motor
If all good  revist head issues.  
Do cams rotate  if installed on head off motor freely or do they bind ???  ( seperate from valve spring  tension  )
Assume nothing  ,,,Check the smallest detail
Use plastigauge  to check cam bearing  clearance
Good Luck nand let me know 
Dave


 

Absolutely agree with you, this is why I suggested the pressure check at the switch housing - any restriction or blockage related to the deleted cooler etc should cause the oil pressure to be higher than normal at this point   whist there is air flow and signs of oil at the head it is difficult to measure if it is anything like the high flow rated expected

As I go through looking at everything, including the books and photos, I have noticed one thing that I’m not sure of. The top cam chain gear idler between the cams looks symmetrical. I’ve seen it installed in my books both ways. I marked mine with an arrow upon initial disassembly. What if it’s backwards? I don’t see how it would cause my problem but worth asking.

The Top Cam Chain Idler can be used both ways! He is made/build to the center of cam chain with no off set any way.
Only the dis-integration of the cam chain gear rubber damper part can cause an off set.

 

I’m going to try a pre-prime setup to fill the upper oil passages before spinning it with the starter.
im waiting for a gauge as well.
im grasping at straws here

wrote:

I’m going to try a pre-prime setup to fill the upper oil passages before spinning it with the starter.
im waiting for a gauge as well.
im grasping at straws here


 

Have you removed the bung and checked for a cooler restrictor as mentioned previously
 

Need to figure out how to do something like this. Not compression testing, turning the engine with an external source

fb.watch/escvlIBDEK/

Yes, l took out the bung and all is clear

Before risking more damage could you make a gasket for the switch housing with no hole on the switch side to block the oil pump, then suspend a container of oil as high as possible above the bike and gravity feed it into the bung hole. Current atmospheric pressure in Hawaii is 14psi. Given that this is a high flow system the container should drain relatively quickly (random I know)
 

Kind of what I’m planning.
bucket test of oil pump, for what it’s worth
 

one more try

Kind of what I’m planning.
bucket test of oil pump, for what it’s worth
 
I was thinking more about a flow test through the motor, with a gravity fed supply to the gallery you could loosen each of the four outer head nuts in turn and see how much flow you have coming up to the head (ref Z1015's advise about HD studs)

1. if the flow is poor consider drilling as advised or replace studs with stock
2. if the flow is good consider removing the gallery bungs on the head as mentioned previously and inspect the gallery's 

I know this problem is getting you down but "stay the course" you have done to much to "give up" you will get there 

I think I mentioned earlier that I once had to tear an engine down completely five times before I found that I had a non standard transmission that was causing the kickshaft to grind on the trans gears.  (It was a close ratio transmission option offered by KHI back in the day, but it required removing the kickshaft.)  It was frustrating but I had faith that eventually with advice from others I would find the cause.  And I did.  The payoff for you will be the immense sense of satisfaction when you finally solve this mystery.