Sorry this is long and semi-methodical:
Sooo...About 3 weeks ago I got my 55 KHK running and went through 4-5 thermal cycles. I decided to rebuild the carb (again) since fuel flow was an issue, disassembled and inspected primary case components due to an unforeseen increase in fluid in primary, and recharged the battery. Well after 3 weeks, I tried to start it again today and progress through the break in. Unfortunately, she didn't want to start and it sounded different, almost sluggish (hard to describe).
TROUBLESHOOTING:
1. Fuel flowing to carb - Yes
2. Bowl float is moving and shutting off flow properly - Yes
3. Spark to plugs - Yes
4. Plugs look clean - NO, black oily soot led me to believe there was some kind of an oil supply issue
5. Check Oil reservoir - EMPTY
6. Check Primary side fluid - Appears normal through viewing port
7. Pull Engine Case Drain Plug - only approximately 1 quart oil (now my head is spinning)
NOTE: Oil had a bit of aluminum looking "angel dust" which I figure is normal for breaking in new engine (thoughts?)
8. Pull Transmission Case Drain Plug - Drains almost 3 quarts of oil/tranny fluid mixture
IDENTIFIED PROBLEM:
1. Oil is draining past pump
2. Oil is getting into primary
3. Other ideas?_____________________
SOLUTIONS FOR PROBLEM 1:
1. Install valve in oil supply line as I see a few folks offer as an idea on this site - dangerous due to non-standard and could ruin engine if I forget to reopen oil supply
2. Re-engineer/install seats on oil pump, etc. (I believe "Lisa" has mentioned this to me in the past, but I thought I would be ok with strict rebuild)
3. Other Ideas?______________________
SOLUTIONS FOR PROBLEM 2 (Based on recommendation by "Frenchcowl"):
1. Disassemble primary side components...AGAIN!
2A. Replace Check Valve between engine and primary (hard to remove as I recall; does it need special tools?)
2B. Replace main crank shaft seal in primary side
3 Other Ideas?____________________
I am a bit flustered after 5 years of working on this beautiful bike and open to experiences insights....
Thanks,
Mayday