White smoke, Oil, Power Loss. Help

Ok - I got all of the parts and started to put her back together. I've heard somewhere that the pistons need to be Top Dead Center during reassembly. Is this true? If so, how do I find this? Also, is there anything else that I need to keep watch for while doing this?

[yorkie_chris]

Put mark on flywheel through timing cover window to F... that is TDC at front. Set your timing marks on front cylinder.

Then rotate engine 360deg (back to F mark) and set rear timing.

Gotcha! THanks.

Bad News -- After many attempts the bike started for about 15 seconds, when all of a sudden i heard CLANK CLANK CLANK. So i shut the bike off and when i tried to start it again, nothing. Just a CLICK and it sounded like it was stuck and coming from the rear cylinder. I pulled the rear plug and tried to turn it by hand I am able to get it to TDC F but not TDC R. But it is turning. So i went to start it again and it made, what i think is a half turn and then STOP. Nothing.

Any thoughts? I haven't removed the valve covers and took a visual inspection just yet -- but my only thoughts could be that the timing is off and the piston is hitting the valves??

[Sid Squid]

Originally Posted by jasonkoscho

but my only thoughts could be that the timing is off and the piston is hitting the valves??

From the description you give that sounds unfortunately likely. Whatever the problem proves to be, don't try to start it again without checking the cam timing first.

for gods sake take it apart. if the valve timing is out then your going to have to take the heads off, from what your saying there are bound to be casualties. you will find the problem without doubt. atb paul

So my rear piston definitely slammed into the valves - the two intake valves are bent and are pressing out a bit. So they'll need to be replaced. So Im thinking that it was just way out of timing.

I just checked the front and its dead on perfect. But when I attempt to rotate 360 to the F again, I cant. I can go about 360, but i dont get to the F and I can no longer turn it in that direction, I have to turn the opposite direction to get them to move again. My question is, "Can you continually rotate the engine non stop? Or will it hit a point where you have to rotate counter clockwise?"

[yorkie_chris]

Counter clockwise is correct way to turn it, but rear cylinder might still be getting interference.

when you have just put it all back together slowly turn the motor over by hand using a socket and short bar do not!!!! go straight to the starter button alway always always check as you go turning over gently to make sure nothing is contacting. some of engines are difficult to turn in reverse i`m not sure on the sv tho. dont forget check , check again and when sure check again works every time. atb Paul

Ok - new piston and new rear cylinder head installed. I still have a lot of smoke. Here are two videos that i shot on my phone. Any ideas?

http://www.75meters.com/0724001553.mov
http://www.75meters.com/0724001554.mov

Much appreciated.