Did you find anything with the pinion gear key. Did is shear or did the cam stop rotating causing the valve to hit the piston. When you installed the Adjustable pushrods are you 100% it was done correctly? What rpm was the motor spinning at before it came to a sudden stop?

As for your other thread on the pinion bearing set, I would just use what's in there currently. I don't see were there might have been damage there. Can you post up pics of the inner and outer races? If any thing I would be disassemble and check the Rod bearings..

 

Pinion gear key came out in one piece. Followed somebodies advice from this forum, used some heat then a very small screw driver under the 'lip' and it popped right out in one piece.

Motor was spinning between 1000 - 1500 RPM's and on it's way down to idle. As soon as the noise got my attention I pulled the clutch and started coasting to the shoulder. FWIW I was doing about 35mph.

I am 100% sure the push rods were installed correctly. I had some practice when I rebuilt the shovel. hydraulic tappets, then solid, then back to hydraulic. The new rods in this evo were originally put in with the Fueling tappets and then again when I put the OEM tappets back in because the Fueling tappets (that came in a box marked "V-Twin") had failed. The bike was running great for just short of 500 miles when this happened.
NOTE: the spots in the 3rd pic down are dust lol

 

If it were mine, I'd line lap the pinion races and refit with new bearings. And as mentioned by 98Hotrod, I'd check the rod bearings and likely do the same. That way you have a rebuilt bottom end that will last a long time.

Paul

 

I wonder if a piece of the failed V-Twin tappets got lodged up in the push rod tubes.

 

That could be, I believe the rear intake was the first tappet to fail. But, I did cut the push rod open and the piece that was inside looked too big to fit thru the end holes in the push rod. I never bothered trying to finish getting it out. I've already thrown it away and I don't feel like digging thru the trash. Come tomorrow when the trash man comes it will be gone forever lol

 

Man, Just my opinion but if you don't get Religion after this,I don't know what a Miracle is. I'd start burning Candles now.......