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It's little, but it's there - just by the main exhaust valve. Zoom in - below the main exhaust port.
How big of a deal is this? I had it open to replace the kips with BDK.. bike was running great upon disassembly.

Wow this is a tough call. As I'm sure your aware it's only going to get worse with time. I think you know what needs to be done... It needs repaired.


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It's not a big deal until it is, which is why I would have the cylinder fixed.

You will never be able to "guess" when the moment comes when that little crack creates bigger issues.


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So in order to "fix" it, We're talking weld, grind, bore, plate, new piston likely.
Ugh. $500 crack right there. Might as well do port and polish too, hehe. Wish RB did plating, then I could send it to him to get dun right.

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Friedom wrote:So in order to "fix" it, We're talking weld, grind, bore, plate, new piston likely.
Ugh. $500 crack right there.

That seems high. Plating should be around $200 and for some reason $50-$75 is standing out in my mind as the typical welding charge.

+ s/h you're right. Around @300.
Hard for me not to order p&p while they're in there, though. And should get a new piston while I'm in there. So.... $500 might make it.

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Tedh98 wrote:

Friedom wrote:So in order to "fix" it, We're talking weld, grind, bore, plate, new piston likely.
Ugh. $500 crack right there.

That seems high. Plating should be around $200 and for some reason $50-$75 is standing out in my mind as the typical welding charge.

Yes... your all in costs for shipping (both ways), strip / weld / plate / hone should be around $250. Of course you'll have the cost of a new top end to add to that.

Yup, mine cost $260 all in (needed welding) from Millennium. Did awesome work. Two week turnaround. Sent them piston and they matched it to cylinder.


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Wonder how I can determine the condition of current piston? It's pretty clean. Is that lazy to send it in for matching? Am I supposed to get new rings even though it had great compression?
Thanks for holding my hand, guys.

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So Millenium's page says that a single cylinder repair is a flat rate of 274.95.
I'm waiting for an email back for verification. They did great work on my last engine, but there was no cylinder repair involved.

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Friedom wrote:Wonder how I can determine the condition of current piston? It's pretty clean. Is that lazy to send it in for matching? Am I supposed to get new rings even though it had great compression?

Unless you know the number of hours on that piston (and that number is low) I wouldnt risk a newly plated cylinder on a used piston.

Get new rings as well

Replate on website say is $209

http://www.mt-llc.com/serviceInfo.php?id=7

They charge an extra $60 if it needs welding, which yours will. When I called they quoted me $199 for replate and $60 for weld.

Repairs service I think is something entirely different I think.


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I looked up the piston on it. It's a nice clean wiseco. Doesn't seem there's any way to assess condition though, eh?

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How many hours are on the piston?

With me? .25. I just got the bike running :)
History is that person A left it at a shop and didn't pay his bill. Person B bought it but it didn't run well. Person C bought from B to help with bills, and person C didn't really want it (has an H series) and couldn't get it working well due to "weak spark".
I'm person D. Turns out the stator was bad. After checking, testing and fixing other components I finally replaced the stator and it fired right up and ran like it should. Except for the broken KIPS, of course. Came to me with new plastics, light, tires, pipe and chain. The head gasket looked new when I opened it, piston too. Someone was throwing parts at it but didn't find the problem. Great compression too, 150+ iirc.

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Friedom wrote:

Everyone's talking about replating. Isn't that a sleeved cylinder? (Looks like it from here. )

Kinda does, huh? I'll get some better pictures to see if we can clear this up.
Is sleeving a cylinder a 1 way transaction?

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Friedom if the piston looks fairly new... I'd reuse it, but I would throw on a new set of rings I'd also monitor the run hours.

I can't speak to whether the cylinder has been sleeved... but I doubt it. Send it out and have redone to OEM Specs put in the piston with a new set of rings and let her rip

I'm sure you checked eBay... The only cylinder I found was over bored. I'm not a fan of over boring as you also need to cut the power valves to match. Personally I'd send your cylinder out to be repaired. It will be better than new when you get it back.

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There's been some work done on this engine over the years. I see a C stamped on the exhaust flange, an 0916028 and 1125047 on top of the cylinder, a 1 near the kips arm, a 1028048 on the water outlet. All stamped custom, definitely not factory.
Going to post a few more pictures to see if it's sleeved or not.

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