Beginning my rebuild

[Nighthawk016]

Okay I need some more experienced opinions on this. From my pictures, how many hours do you think are on this bore? I have no idea and have no way of knowing.

[kdxdazz]

Impossible to know how many hours on it but looks a bit of a mess, that chamfering is terrible, at first I thought it was sleeved but looks to be nicasil,

[Nighthawk016]

Impossible to know how many hours on it but looks a bit of a mess, that chamfering is terrible, at first I thought it was sleeved but looks to be nicasil,

I am positive this is original, so this is how kawasaki shipped it

[SpruceItUp]

Hard to tell how many hours just by looking unfortunately. It could have been fewer than you may guess if the air filter was rarely cleaned, but it could be more than you might guess if it was taken great care of. Too many variables at play to make a safe assumption.
Definitely time to send it to get replated and maybe get that chamfering cleaned up as well, I'm surprised it came from the factory that way.
Good thing is that it will pretty much be like new once you send it to get replated.

[Nighthawk016]

Found a spot where my plating is coming off, Good thing I planned to send it off!

[Nighthawk016]

Fully tore down my cylinder, its a bit fiddly. I may have lost the spring that puts pressure on the ball bearing, ill have to see if I can locate that!

[Nighthawk016]

I chose to get some berrymans chem dip to clean everything up. I got these parts cleaned up, the main powervalve is back in soaking, it was really caked on. I may have damaged the packing on the kips rod, I will have to figure that one out. I'll post more once I get the powervalve clean. I

[Nighthawk016]

I've been stalled for a little while, I got my new wossner piston, in the A size. I've been waiting on my cylinder from millennium, that shipped back to me today. Then im waiting on pro action to finish rebuilding my spare suspension so I can install that.

So, updates soon!

[Nighthawk016]

Got my parts laid out, ill hopefully get the cylinder reassembled today!

[Nighthawk016]

Alright, more updates. Lots of progress made! I got the cylinder reassembled, timing the powervalves was actually more simple than I thought. Started prepping my piston and rings, I goofed and filed one of the ring gaps too large, so I had to order a new ring, not a huge issue. And today got it all together and torqued. Final assembly and heat cycles will like be Friday, maybe Saturday. Ring gaps both ended up right around .35mm or .014" roughly.

Special shout out to Jamiethegiraffe for sending me the oring for the sub valve shaft!

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[Nighthawk016]

More pics

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[Nighthawk016]

Got around to installing the silicone hoses and got the rads installed yesterday.

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[Nighthawk016]

Then today I got the bike assembled, did my heat cycles, and took my first ride!

[KDXGarage]

Congratulations on getting it all together so well! Have fun on it.

Friendly reminder to everyone who didn't already know. The aftermarket plating shown is beautiful. A new OEM Kawasaki Electrofusion coating cylinder does not look like that. Over the years, I have seen a few people say comments about cross hatching being gone from the OEM cylinder. They expect it to look like the one shown. It is different /fairly smooth compared to aftermarket nickle silicon carbide. :-)

[billie_morini]

Nighthawk said, "Then today I got the bike assembled, did my heat cycles, and took my first ride!"