It's an 07 carby, I could hear a slight tapping noise but nothing major. Honestly at first I though I had bent a valve when the bike stopped. For carby settings I couldn't tell you at the moment, the bike is at my brothers place but I will tell you the settings when I get to rebuild it.

 

Blown head gasket. Loss of coolant will toast a piston, especially when we get 38 degree days.

 

What does the crankcase oil look like?

 

I'm with WestOz on the cause of this failure, it's still not clear as to exactally what happened but it sure is easy to say it was from a lean condition. Remember Jhoffy he was told the samething although it was clear a valve had tried to go through a piston.

 

Seems pretty clear to me that it overheated.... either by no coolant or lean... it melted.

 

Did you notice white smoke coming out of the exhaust at all?

 

I'm going to take a guess that the PO put a pipe on and opened up the airbox without jetting. Some folks can bolt on goodies but not good enough to did into a carb. OR, he jetted the wrong way.

 

Not an issue on the AUS bikes , they come with the KLX300R carb' jetted and all. #132 main #35 pilot. No one would put a #118 in when it's already got a #132 main.

 

I've been trying to call Bill with no luck, anyone know an email address or someway to contact him?

 

I think Bill goes away on holiday’s alot, but he will answer you eventually. Just leave an email.