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I have a 2001 KDX200 that has the original piston and cylinder plating.

I'm in the process of doing my first top end rebuild and after cleaning the cylinder with a scotch brite pad
I can't see any sign of crosshatching. It just looks like smooth aluminum, no deep scratches or anything.

I'm the second owner on this bike and from what I can tell it hasn't been ridden hard. But, it's difficult to say how many
hours the original owner put on it.

Should I go ahead and get the cylinder re-plated while I have it all torn apart?

Is there any disadvantage to doing a re-plate a little early versus waiting until the cylinder is very worn?

Note: I'm replacing the piston/rings a Wiseco Pro-Lite.

Electrofusion does not have the same level of cross hatch scratches as most other brands of plating, so keep that in mind.

Do you have the cylinder out now?

Measure the bore diameter and compare to spec.

Jason wrote:Electrofusion does not have the same level of cross hatch scratches as most other brands of plating, so keep that in mind.

Do you have the cylinder out now?

Thanks Jason. Yes, I have the cylinder on the bench.

Can you post pics?

You may want to look at google images as well. I have a new E series cylinder (not close by), and it does not have much in the way of cross hatch. When these guys show pictures of replated cylinders, it looks like bear claw marks compared to Electrofusion.

I was in the same situation as you. When I did the top end on my 2000 KDX220R the cylinder was smooth so I sent it to Millennium for replating. My thought was the bike was already over 15 years old so why not freshen the cylinder up? Do it once and do it right.

javjacob wrote:I was in the same situation as you. When I did the top end on my 2000 KDX220R the cylinder was smooth so I sent it to Millennium for replating. My thought was the bike was already over 15 years old so why not freshen the cylinder up? Do it once and do it right.

I second this. I just had mine replated at Power Seal USA and now have restored confidence in the integrity of my engine. Well worth the $200 price tag.

i had the same question. even posted some pics on a thread here. I measured with a dial bore gauge and it was in spec. i decided to to just go with it and do it later.

But its a personal call.. if this is your daily rider I'd probably do it. This is a specialty bike for me( 1 of 3 ) so i'm not as in big need of it being "tight" good enough is fien by me

doakley wrote:Measure the bore diameter and compare to spec.

Thanks doakley. I had a machine shop measure the bore. It's within spec.

Jason wrote:Can you post pics?

You may want to look at google images as well. I have a new E series cylinder (not close by), and it does not have much in the way of cross hatch. When these guys show pictures of replated cylinders, it looks like bear claw marks compared to Electrofusion.

Hi Jason,

I can't seems to get any good pictures of the bore. They really don't show enough detail.

Thanks for mentioning that Electrofusion looks different than those replated cylinders.

Electrofusion is applied differently.