I've been plugging away at this for the last few weeks but it's still not in a good state. I learned that the crankshaft is out of true, both sides bent enough to cause the binding, and sent it to a machinist I was recommended. In the meantime, they also worked on the cylinder and ordered a new piston set. But, turns out that the connecting rod is also done for; too much play in the small end that would cause the piston to knock.

I'm very stuck at what to do next, since parts for the crankshaft would be about $400 plus ~$500 for the piston kit and machinist's time. I also still need bearings which are another $300, on top of everything else I've already bought for this thing. I'm not sure how far is too far in a project vehicle and would really appreciate some thoughts on the matter. I could have pretty much bought a brand new bike for the cost of parts/labor/my own time on this thing.

They don’t make old bikes any more.

It is never as much fun going in the second time. Especially when one needs to cough up cash to make things right. This is part of the experience of resurrecting an old, dead motorcycle. One takes some risk when they shell out a few hundred dollars. You just don't know if it's a bargain with a bad spark plug wire and all the costly systems functioning or if it was run until it's heart gave out with collateral damage along the way.

But that doesn't change the vision one has for the finished product. It becomes a test of one's willingness to invest to bring that vision into reality. It's true that all that money and a whole lot less fin-scrubbing-sweat-equity could purchase a newer, running bike. But it would likely be one that can't fulfill the vision you have for the XT.

I'm sure many (if not most) of us in this community have been where you are at least once. I personally have invested more in all old motorcycle than I could get back.I And have three more in que. But I didn't invest to make money. I wanted the experience of building, riding and owning certain motorcycles. 

I known I speak for others in this community when I say I  appreciate you sharing your journey with us. For those of us who have not dug into an XT before, you are educating us. It's unfortunate that we can't answer all your questions with multiple responses as would likely be the case if it was a DT.  But we would still like to see you win.

Len

Sounds like to me you have already started the rebuild. I say stick with it. You'll have a trusty bike once done. Also, don't overlook the valves/lash etc. 4 strokes are sensitive to lash.

If the engine is eating pasta, then what do the bearings/bushings in wheels, swing arm, steering, look like? Check spoke torque, brake shoes/disc pads, fork oil. New tires? What about tubes? The schrader's break down.

Len,

Thanks for this. I did some of my own thinking the last few days, really figuring out why I bought this bike in the first place. It's only my second bike and man, what a choice for the first one I need to actually dig into it is. But I didn't buy it with the thought of fixing it quick, riding it, and dumping it. I really bought it to learn how these things worked, and figure out how to fix them in the first place. Heck, I've never even ridden offroad before either. (Also, I bought it because it was purple, that's awesome. Nobody makes stock purple bikes anymore )

I did eventually decide to bite the bullet and buy the needed parts to continue. It'll probably be a few weeks before I get them in and then to my machinist, but it'll be done proper and won't be in the hands of those who wrecked this bike in the first place. Everything with this has been a massive learning experience, with far more lessons to be taught. 

As for frame and other non-powertrain parts, I have not looked into them just yet but absolutely plan to. My original thought was to get the engine running as a minimum entry point and then start going through the less difficult (but still critical) parts as well. I haven't torn down the wheels to check bearings or brakes, but I'm planning to treat everything as trashed due to the exceptionally poor way this bike was treated in the past. Wheel bearings and brakes are far cheaper than hospital bills. 

One piece of good news is that the tires are brand new, likely unridden. I haven't checked the date stamp on them, but they have no wear. I'll go through and check spoke tension too, another new thing to learn. 

A fun hobby. It all takes “hands on” time.