if you find such a thing do tell me and post its picture here

Lol; sad truth. But what to do? I'm unable to find one. The first guy is evading due to lack of people & somehow I feel he's overcharging
The second guy is asking 20 days simply without knowing things
The third guy looks at the parts passionately but he's unable to come up with what needs to be done; he simply says he can do it but neither has done before nor comes up as how to handle things.

Meanwhile, I've decided to add up more to collection such as RX100 sprockets, few additional bolt & nuts. I'm delayed, but not given up

good luck argee ,no matter how careful you are there will be something that will be missed and will be needed at the last moment, learnt that the hard way during the kb rebuild

Well may be; but the idea is to minimize the stranding time, means if the work starts it SHOULD complete it within the stipulated time.

Another approach is to spread out the build. Like, assemble the parts one by one so that we have individual components built up & then finally assemble everything in one go.

The main reason I cannot keep it in garage is all the parts are hand picked & it really bring blood in my eyes to see someone cheating. So I cannot afford to it. So whatever is being done, it should be done right in front of me & hence cannot afford to lock it up in garage for few days.

Have been thinking hard on this one & finally came up 2 different approach.
Approach 1
Is it possible to fix the entire engine & mount it on the frame in one go? What I intend to carry out is, fix the engine bearings on the inner casing, 5S Gears, Crankshaft, Clutch assy, Kicker axle, front (16T) sprocket, fix the piston to the con rod, 12 V dynamo & finally the outer covers for the engine casing. After fitting all these, is it possible to remove the existing engine from the frame & then plonk the new one?

Let me also explain as why I'm asking this. The idea being, to fix the new engine completely & on one fine day, remove the existing engine from the frame, plonk the new engine into the frame, fit in the existing cylinder & the new head in one shot. This way even if the entire engine build takes 2-3 weeks due to one or two parts missing, I'm fine with it because I still have my ride serving the purpose.

Finally when the new engine is in place, I can start replacing all other parts may be even myself over several weekends from fenner to electricals.

Pros - Since the build is spread out, even if some parts are missing, I've good time to order them & the bike remains untouched; I get the entire engine as brand new one except for the cylinder.
Cons - Once again the bike needs a run in period & this will be like the second running in period over 13K Kms which I'm not that comfortable. But willing to agree if no other choice.

Approach 2
Keep the existing engine as such until the inner most cover. This means, do not touch the inner most engine casing, crankshaft, engine bearings, cylinder, head & piston+rings. Replace only the 5S gearbox, clutch assy, kicker assy, 12V dynamo. This will be a weekend's job.

Finally when things are replaced inside, I can start replacing all other parts may be even myself over several weekends from fenner to electricals.

Pros - I don't see any missing parts & even if I do, I can replace always from the existing. The bike doesn't undergo the running period again.
Cons - I don't get a brand new engine as the crankshaft, con rods are not replaced. Again one question remains, as if its possible to replace the entire clutch assy without touching the crankshaft & above assy? If not, then the clutch will remain from the old part & all those parts that does not involve in dismantling the crankshaft & above will only be replaced.

Please help me choose one of the best option as I'm literally confused. Thanks.

What I can suggest is that, take off for 2 or 3 days (if possible) get the rebuild done at once.

Remember that changing part by part would take our time over a period.

Even if you encounter some missing parts, you can always take it from the existing set up and later replace it with new.

You're more than right. I'm so confused that I couldn't even think in these simple lines. I guess I need to apply leave or work on weekends.

try doing it on fri and sat so that if u had missed any part you can buy it besides if any sort of machining work or so is required you can get it done ....do not let the mech postpone the work once you begin no matter what ,and old murphy will give you company

@KB100 - sounds easy my friend, but trust me, its very difficult. Murphy is no way in picture as this is my daily ride. I'm spreading the build out so that I can have the ride, test it as well as rebuild it. If things work fine, the engine rebuild should happen next weekend (not the forthcoming one - yeah Sri, tough times!!!) & after that there's something for which I should run around - Front fork fix

The remaining things should be easy as the replacements are only for wheel bearings both front & rear, swing arms, bar tension, exhaust assy, front & rear fenners & finally electricals. Having changed the entire intake manifold, I hope other things should be easy to accomplish!!!

i know that argee been there during the kb rebuild and that too despite being a complete one in a single go and murphy will always be around when you are doing such rebuilds ,since you are going for the engine rebuild only it should be over within a day,whatever you do do not let the mech slack off ,the remaining ones seem to be easy

ps; can we assume that you have finally found your mech

I'm trying to keep off murphy as much as I can but in a different way. Like when I was replacing the intake manifold, I couldn't put back the new stuffs on the same evening & I was able to fix it back only the next day. But there's a world of difference when murphy visiting my home compared to the mech's garage isn't it? All I need is that peace of mind with the spare parts.

Arey baba, not yet with all the qualities I asked for. Probably you can say this mech is confident + competent. Since I give him work only in bits & pieces, I choose to stay with him when he works rather than leaving the motorcycle to him. I don't want to take chances; what I assume is, by the end when I put all the things back into the motorcycle, I might learn as well how to do a regular service; that way I can completely keep off from all the mechs - what do you think?

Status as of now
Replaced parts - Reedvalve, airfilter assy, kicker lever, kicker shaft, tank, seat, side shields

good luck argee ,do take a camera with you and do take shots of the procedures involved, will come in handy later on when you decide to go solo,as pictures can give a better idea of the steps than the figures in the workshop manual

Quite difficult @KB100 as hands will be covered with grease & oil & can't bother Wifey to take pics.

WOW!!! What a productive day!!! Had changed the rear swing arm, bar tension, brake rod assy, wheel spacers, puller assy, centre axle, rear axle, left & right L brackets & all bolt & nuts. So except the wheel bearings & rear footrest everything else is changed. All this besides the engine number etching on the centre casing. Took about 4 hours to get this done; started when it was burning sun & ended up when it was raining!!!

Edit - Yesterday I was at HMSI showroom at Velachery for buying Unicorn spokes & guess what happened? They say that they don't get those parts (Something rhyming Sri?). I'm tired of hearing this answer over & again. I guess this is the problem with this entire country!!! Anyway, enough of OT. So I'll be trying with Pulsar's spokes, which I again think may not be possible. If this also fails, Plan C is to fit in good old Splendor's spokes.

The engine work is planned to be carried out by next week & the frontal work (Suspension, wheels, meter assy, pilot lamps) the week after that. Hope God doesn't dispose!!!

What a great lesson as why all or related parts must be changed & no Indian juggad should be done!!! After fitting in the wheel, I took out for a spin & without even changing the bearings I could feel the difference in the ride quality. Fittings? I don't know what to say. Everything fits in a perfect line, I mean the spacers, puller assy, nut castle & the wheel; there's an exact gap of few mm to fit in each of the part otherwise, previously, I'd to do push & pull work to get them all fixed.

I'm glad that I changed the swing arm because I could see the above difference & gives me a feeling that the old swing arm might've been slightly bent. Great lessons in this rebuild or...

will be a good idea to chrome the new spokes before installation.Just my 2 cents