Regrettable Engine strip down !!!! I think " Follow up". But it's not over.

Scotch, this was a genuine kawasaki

Hi Kawboy, thanks for your reply. Checking the valve stems, the only thing i found in the book was about reaming the valve stems. I will look into this now. 
 Gasket, the one i used was a genuine Kawasaki. But cast your mind back about 6 months, when doing the top end re build. I found both valves on #6 slightly bent ! so they were replaced and we re used the gasket but this time with sealant. If this has caused a problem ?
Coolant, no loss of coolant at all.  So smoke I cant tell you how bad it was, Casey Jones comes int mind !  left hand side really bad. My exhaust system is not original , the 6 headers are a push fit under the engine. At this point with the engine running, oil was coming out of joints1-2-3 and pooling on the floor. The silencers are slash cuts, on the L H S a build up of sooty oil of about one eighth of a inch . The picture in this post is from the best side, if you can call it that 4-5-6.
The bike for years has always smoked fowling up plugs. But this time its so much worse. Do i also at this point take off the cylinders and look at oil rings ??? 
I just want in as correct as i can. This bike is the girlfriend you love but she don't love you !  if it was any other bike, it would of been gone a long time ago.
So many thanks again for your help.  
 

Reusing a head gasket- Asking for trouble. The only head gasket I know of that are reusable are copper head gaskets and you have to anneal them before reinstalling. I digress.

If your oil signs are pissing out the exhaust pipes, you're bleeding oil. Sounds far worse than just valve stem / guide issue but at this point don't discount. Check, check, check.

Was there any sign of oil seepage from the 4 ports around the cylinder head studs at cylinder #3 & #4  suggesting an internal head gasket leak allowing the oil to find its way to the combustion chambers?

Then being the Devil's advocate, that much oil showing up in the exhaust and yet the bike is still running on all 6 cylinders? Sounds impossible unless the oil is bypassing the combustion chambers and finding its way into the exhaust?  Haven't heard of a cracked head but never say never. You've got a very unusual issue going on here.

I'm going to stand on ground and say for sure, you have valve guide / stem excessive clearance and or, the valve stem seals may not have been installed right- meaning they're cocked on the guides and not sealing around the valve stems properly and I base that on the carbon I see on the intake valve and the carbon in the squish areas in the intake side of the combustion chambers, but oil pissing out of the exhaust pipe and dripping on the floor is another matter.

Was there oil accumulating in the airbox from the crankcase ventilating System? That would also tell me that the piton rings are passing. (I wish you had done a leak down test before the tear down but in lieu of that I ask this)

I feel your pain. These kinds of issues can happen when you go into a complete rebuild since a number of changes happen all at once, Take your time. Think it through. Hopefully I've spurred some thoughts here that will help. Maybe take a bunch of pics and post them. Extra eyes on the problem may help as well.

Finally, thanks for sharing. Topics like this can help us all learn through others experiences and makes us better mechanics.  I wonder if AI will ever delve into this area, then God help us!!

Brixamoto sells head gaskets made by ATHENA 
 
 
The irony ?
 
Canada Post's data base didn't recognize the return shipping label nor the Swiss (?) carrier "Asendia" !


 

Hi Scotch, I have seen and heard about these gaskets. I decided on a genuine Kawasaki. That's what was installed. But after the first head re-build everything was torqued down. Decided to do a leak down test . no compression on #6. somehow these valves got slightly bent. So we re-used the head gasket. Bike had not been started at this stage. but the second time of installing the gasket, I used sealant. !!!!!

Just out of curiosity:  Was the Cyl. head "shaved" ?  (Machine-shop work)