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I recently acquired an 04 KDX200. It was making more noise than I was comfortable with so I tore it down to do the top end and clean the gunk out of the kips. I found some excellent write ups in here after I broke the governor rod and hit google to find out what I messed up. When I pulled the jug, the walls didn’t look terrible but I noticed the skirting around the bottom of the cylinder is chipped. I’m assuming it was dropped during a service at some point in its life, it ran good when I tore it apart. Is this something that could be ran or am I just begging for catastrophic failure doing that?

I would just file / grind / sand that down. Do you have or can you take, some pictures of the clean bore? It looks really bad in those pictures. By that, I mean the cylinder wall surfaces.

KDXGarage wrote: 05:58 pm Mar 29 2025 I would just file / grind / sand that down. Do you have or can you take, some pictures of the clean bore? It looks really bad in those pictures. By that, I mean the cylinder wall surfaces.

I’m a fairly untrained eye but it doesn’t look good to me, any insight is appreciated

Sorry, but that looks like a replate to me. It is like it has cavities on the side, in addition to the other wear.

It's the opposite, cylinder wall looks terrible and there are no chips at the bottom of the cylinder

You need a replate & piston kit.

PowerSeal USA or Millennium Technologies replate job is in order. Wossner or Pro X or OEM piston... Check the play in the big end connecting rod bearing on the crank as well with the top end off.

If that's good, either piston slap or KIPS powervalve noise is what you were hearing.