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You could probably ship the complete engine to the states and have someone rebuild it and ship it back for half of that price!

Yeah I was a bit shocked when I got the quote back.
Apparently all the seals are OEM which is why the cost more.
They were shipping it to the US to get recoated, no idea where though.

Postigo wrote:I think the 1988 KDX has an iron cylinder instead of a nicasil so you can hone your cylinder or cut it to the next piston size instead of replate it.

I thought you couldn't do that, you would need to run a sleeve inside instead?

screwloose wrote:

Postigo wrote:I think the 1988 KDX has an iron cylinder instead of a nicasil so you can hone your cylinder or cut it to the next piston size instead of replate it.

I thought you couldn't do that, you would need to run a sleeve inside instead?

you can overbore these bike up until a certain size (I think my 96 is overbored by 2 mm which is the max)
once you get to that point you start to loose structural integrity and you need to install a sleeve to bring the bore back down

so if a mechanic looked at your cylinder and told you you need a sleeve I would guess the bore is damaged beyond repair, or maybe it has been overbored before and that's why you need the sleeve

I found someone selling an 86 fitted with 220 big bore kit, pro circuit exhaust, modified throttle, had a top end rebuild 20 hours ago. Also comes with spare fuel tank and spare plastics kit for $2000. Only catch is that its in WA and I'm in VIC.

Am I better off getting that and use the other as a donor bike?

Hey Guys,

I'm happy to report she lives again! :D
I ended up going with the full overhaul and very happy with the end result.

Defiantly feels a lot happier, responsive and sounds awesome! :)
Can't wait to get it back out there.

One thing is the suspension feels like it needs some tweaking.
Is there any tips or guides on how it should be best setup?

Get the suspension mechanically sound with correct spring rates, then go from there.

Ok thanks. I'll have to wait until the new year through.
Most places are closed here or way too busy.

It seemed to be ok before the rebuild, so not sure if they slacked it off for the install or not.