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My 2000 kx 250 cylinder had a sizable chunk missing from one of the transfer port bridges. I used a small file and 2000 grit sandpaper to blend the chunk out, but now that particular bridge looks thin. Ive attached pics of both side's transfer ports as a comparison.
Untouched side:

Damaged side:

As long as the locator pins don't sit the rings there I don't think it will be a issue. Cylinder looks sleeved anyways.

Make sure you clean up the burr in that right port in the top pic.

Its a sleeve. Ive sanded out the burrs around that port also. Ill probably use the cylinder until I get a non-sleeved ebay cylinder and get it replated.

I have one from a '99 at home that I'd be willing to sell.
Let me look it over tonight and see what condition it is in and what the bore is.
I'll pm you some pictures later.

doctord23 wrote:I have one from a '99 at home that I'd be willing to sell.
Let me look it over tonight and see what condition it is in and what the bore is.
I'll pm you some pictures later.

I got laid off from my job last week, so I may end up HAVING to use this cylinder, which is why im worried :) send pics anyway though.

It'll run.

hit it with some acid and scotch brite itll be ok

I put a ring through it and checked end gap and it looked like it still has a good seal. I chamfered the high spots around the ports and it looks good. Thanks!