Few years ago my s1 stripped the oil pump drive gear 1 months into me owning it just before going to TT. I replaced the gear for bronze upgrade, cleaned up debrie but put faith in god as did not have time to strip engine to make sure crankcase was clear of debrie. 1200 miles later the oil pump picked up a bit of the old gear which siezed and stripped the bronze gear. I parked it at the back of the garage and didn't touch it for 2 years (apart from robbing the v&h can off it for streetfighter i built).
Now to present day, I've stopped sulking and forgiven the bitch and want to get all buelled up again! i've got the engine out and stripped and find on closer inspection the damaged doesn't end with just a stripped pump gear and oil pump. It must have picked up some of the debrie between the cam gears as all the cam bush's in the crankcase are worn (I wriggle the cams up and down). All the cam bush's in cam cover seem A good close fit though. The worst bit is I've got a small crack in the crankcase about 3mm long at 10 o'clock on front cylinder inlet cam hole and bush is not a tight fit in caseing. I think I'm going to have to have the crankcase welded and bored to oversize and have oversize bush machinedup and replace the other worn bush's and have it line reamed.
I would think maz and tubbs could deal with this but I'm miles away in w.london. i've got a few doors to knock on in mind but i wonder if any of you know anyone with the kit to do the line reaming in london. That completes my tale of woe. . i'm going in the corner to cry now.

Box it all up and send to Maz.

No, dont

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Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR

I near fell of me chair

Tubbs has milling machines and lathe etc in the workshop ... ask him, he is in Poole, Dorset

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"With square conduct, level steps, and upright intentions ..”

....and the very close proximity to the RH main/pinion bearing outer race, means that any welding done will distort the race.
As the running clearance for that bearing is 0.0002'' the outer race will need removing, the bore re-machined, a new race fitting and then lapping to size.

I'd start looking for another engine if I were you

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Mithered ta death.
92 MB
96 S2T
98 S1W
00 M2
01 X1
03 P3
10 CR

All sounds like yet more evidence to warm up the engine up thoroughly before high revs are used , maybe the cold, thick oil gives the pump drive gears a hard time

This looks bleaker and bleaker. Had a local engineer look at it but he couldn't deal with the line reaming. Going to talk to a couple of local harley specialists to see if theres a local engineers that can deal.
I've sent tubbs a pm to see if he'll have a look at it for me if I can't sort this locally.
New engine Maz? Surely its got to be cheaper to repair than pay a grand for an unkown engine, the rest of the engine looks spot on, still got honeing marks on cylinder bores.

pm back at you, i love a chalange, if you get stuck come on down.
i think we can do something with it

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Do you want it right or right now ?

Found someone local that can deal! Apparently theres not many people that can deal with this. Went into Nick Gales (one of the good guys) who said snob is only guy that can deal in london. Snobs got the plate (£800) and quoted me £400 plus vat to do whole repair but got this feeling it wont end there as he kept knocking on about £500 crank rebuilds! I think I'm going to take a trip down to sunny Poole and let Tubbs have a look at it for me.

I once holed a piston in a bike and rebuilt it using new bearings everywhere except the big end, which I'd flushed thoroughly. Within a few miles this bearing failed and I had to rebuild again. If the oil has deposited any debris in your b/e bearing, then it may be on borrowed time Imho.
A good s/h motor, as Maz suggested, would probably be your cheapest option.

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If your dreams don't scare you, they are not big enough.

Cavey, take a Tuesday off and amble down to Poole quay after visiting Tubbs. Could be a couple of thousand bikes on a decent evening, maybe even a Buell or two.

Bad luck about your bike. Sounds like what we used to call a Friday afternoon special.

You could nick an engine when no-ones looking

Can understand what your saying Adam but I can't see any evidence of contamination to bearings, bore or top half. Oil gets picked up by pump from crankcase and goes through filter before it goes anywhere else. Only chance of contamination is to front main but it looks perfect. I'd rather tubbs looks at it and I can believe what he tells me as I have trust in what he says (maz also) from reading apraisals over the years from people on here. If I feel my belt getting loose I think my pants are going to get pulled down and no one pulls my pants down except mrs cavey and I feel snobs allready looseing it, know what I mean? I think Maz may be right with regard to 2nd hand engine but lets see what tubbs recons 1st hand casting his eye over it. If I can get away with just the repair all is good but if we're talking crank rebuilds!!

That's fair enough but the ONLY advice that I would rely on about your motor would be from Maz or Tubbs

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If your dreams don't scare you, they are not big enough.