Looking for some words of wisdom

In an attempt to remove a broken exhaust stud on my 82 XJ650J I managed to bugger up the hole in the head and now am looking at taking it to a machinist to have the hole repaired. However before I dive into that job I'm looking for some suggestions. This bike didn't run when I bought it. Right now the engine it out of the frame so I can but a fresh coat of paint on the frame, and was wondering what the recommended next step should be. Should I put the engine back in the frame and get it to run before taking it apart or should I just go for it now since its already apart?

For some background its only got 15000 miles on it and sat for a few years before I purchased it.

 

Run a compression test on the motor (as long as the starter is in it all you need is a battery and an assistant) then decide if it's worth it.

If it gives good compression then pulling the head won't affect its ability to run afterward; however you don't want to go through all that only to discover a ring or piston problem after putting it back together.

Better to have some good data before ripping it apart. I would have gotten it running before doing ANYthing; or at least tested the compression.

 

Ok compression check complete and kinda iffy :?
1: 100
2: 85
3:100
4: 90
There was no change after adding a bit of oil to each cylinder, so that would lead me to believe that I have a top end issue but I could be mistaken, and after looking in the intake and exh ports more closely looks like she was run really rich lots of carbon buildup.

 

Check the valve clearances; if you've got super tight valves on 2 and 4 it could explain it; or they could just be stuck from sitting.

Also check compression again with a different gauge. If those numbers are confirmed it's not a very happy motor, and not going to run without having a go at the upper end including rings and cylinders; unless the valves are all stuck open. (Which I kinda doubt.)

 

Ok I'll take a look at the valves, I was actually thinking about doing the complete top end anyway since I have to pull the head to have it repaired, I didn't really want to go this far into the engine but if I'm going to pull it apart I may as well do it right....

 

Well the valve measurements are as follows
1: Intake <.005 Exhaust .006
2: Intake <.005 Exhaust .005
3: Intake<.005 Exhaust .006
4: Intake <.005 Exhaust .008

All measurements are in inches and the reason I didn't go further with the intake valves is I need some smaller feeler gauges the smallest I have is .005
I'm waiting for my service manual to show up before I start taking the engine apart so are there any other checks I should perform prior to taking the plunge?

 

Ok so with some smaller feeler gauges exhaust valves one and two are reading .003" and three and four are reading .004" also the readings are confirmed with a second gauge. Any suggestions? Should I just bite the bullet and do the complete top end while I have the head off?

 

If you were lucky enough to get-out all but one fastener, ... have the Machine Shop:

Do the Valves.
Lap, Reface or Replace as necessary.

>>Install a Set of New Valve Seals.

Chase each Threaded Hole for Manifold Fasteners.
TREAT each Fastener Hole with Anti-seize Prevention
Install NEW Exhaust Studs with Quality Hdwe.
Provide New Quality Hdwe for Intake Manifolds.

Port and Polish if you think you'll get Performance gains.
Or, ... just to be able to brag that you did.