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ubercooper 08-06-2012 12:28 PM

KTM 300EXC cylinder walls ok? (pics)
Im doing a top end on my 00 300 and noticed the cylinder walls looked worn... Is this normal?

There is no actual scoring, but Im wondering if it will be ok with a good cleaning or I should it sent off to be re-sleeved/plated ?

Thanks in advance

2trally 08-06-2012 02:24 PM

Its hard to tell from a picture, but it might just need to be honed.

ubercooper 08-06-2012 04:36 PM

Here are a few better pics of the 2 spots I am worried about.. I will try honing it tomorrow and see what it looks like... I have also heard of people deglazing the cylinder but that might be more trouble than its worth

Twin-shocker 08-07-2012 12:12 AM

I would guess that either the piston is totally worn out, or more likely dirt has got into the motor somehow.

You wont be able to hone Nikasil using conventional stones, but you can use them to remove material form a seized piston though. If the piston is worn/damaged then it would a good idea to get the cylinder re-plated, and if it looks like damage has been caused by dirt also check bottom end carefully.

ubercooper 08-07-2012 12:15 PM

Thanks guys.. Ended up going with a replate from PowersealUSA

Shocktower 08-07-2012 03:01 PM

I have heard in England they use Nail polish to repair those

:hide I am J/K Twin shocker :D

Foot dragger 08-07-2012 03:03 PM

DIAMOND HONE! Thats what the shops use,1 very quick pass is all it gets,if the tolerances are there its good to go.
That does look like a good amount of dirt ran through it.

Twin-shocker 08-08-2012 04:41 AM

Where can I buy a diamond hone? Wok on Nikasil motors quite a lot and it would be a useful thing to have.

PSchrauber 08-08-2012 01:23 PM


Originally Posted by Twin-shocker (Post 19310709)
Where can I buy a diamond hone? Wok on Nikasil motors quite a lot and it would be a useful thing to have.

Here for example:

Twin-shocker 08-09-2012 09:37 AM

Thanks..............looks way too costly for occasional use though? I get the feeling that something like a flex hone might be more suitable?

Pmason 08-14-2012 07:28 PM

From my research at ktmtalk, I decided NOT to use a hone on my cylinder. Most recommend using dawn soap and a green pad to remove the glazing. If you have any scoring or scuffing (something you can catch a nail on), a replate is the best option.

Ever Onward 08-15-2012 11:36 AM

Good idea, because if you hone the plateing to thin on the high spots, you run the risk of flakeing.

You can even start with the red pad before the green to clean up quicker.

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