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Old 11-22-2012, 04:47 PM   #751
DougZ73
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Quote:
Originally Posted by RideFreak View Post
I do the z setting with the rings off, figure out the gaskets and install the rings just prior to final reassembly. I've seen a ring compressor that would work on the 300 (about 1/2" top to bottom) but truthfully once you figure the cyl install out, proper installation takes a couple seconds. Now the piston pin clips are a different story, the stock KTM units are a huge PITA. Why did they go away from the old style that worked with a pair of needle nose plyers.

Yeah I know, the old ones are still available.

My hardest cyl install was a VW waterboxer, seperate cyl liners that fit down into a non removable waterjacket that pretty much blocks all access for a mortal like me.
Damn...that is genius. I should have thought about doing the Z gap setting with out the rings in the piston. That has just changed how I will do top ends forever.

Probably would have saved the issue I have now. ( bangs head on wall)

Thanks for the tip RF.
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Old 11-23-2012, 02:18 PM   #752
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Found where my compression went.


Not 100% sure what scratched it. Rings seemed to be correct spot and not broken at all. Cylinder looks worse than piston too. ????

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Old 11-23-2012, 03:00 PM   #753
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Looks like a cold seize.
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Old 11-23-2012, 03:39 PM   #754
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Looks like a cold seize.
Cold seize?? Please define. I am somewhat new to 2T's, and have never heard that term.


This is piston:





other side:



head seemed to be in good shape:




So, what is opinion on best method to get this fixed?? Powerseal USA weld, rebore and Nikasil again??? Eric Gorr Iron sleeve and overbore( that is what I had on YZ125)???
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Old 11-23-2012, 04:11 PM   #755
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It looks like something got caught in there, the grooves look pretty deep for just a siezeure. To me it looks like whatever did that caused the ring lands to lock the rings up against the piston resulting in blowby. It that point it's a lit fuse.

The cyl grooving looks pretty deep, I don't think you'll get away with relining the cyl. I've heard they can can do a weld repair of some types of damage prior to recoating it.
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Old 11-23-2012, 04:25 PM   #756
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Yeah, looking at powerseal pricing now. looks like it will be a weld repair, rehone, and new nikasil coating.

I also just pryed rings off piston. Looked like they were lined up right and pins did not fall out or break off.

Still not sure what caused the really deep scratches.
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Old 11-23-2012, 04:41 PM   #757
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Originally Posted by DougZ73 View Post
Yeah, looking at powerseal pricing now. looks like it will be a weld repair, rehone, and new nikasil coating.

I also just pryed rings off piston. Looked like they were lined up right and pins did not fall out or break off.

Still not sure what caused the really deep scratches.
Was the motor open awhile? It almost looks like something came up from the bottom end, possibly something that fell into the motor. The problem with that scenero is the item in question, is it still there, are there more pieces? The fact that the head looks fine sort of goes against that theory. Usally you'll see where gouges and pits develop in the head if there's something bouncing around in there.
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Old 11-23-2012, 04:42 PM   #758
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Did you drop something in the bottom when you were in there? Old circlip or something???
It almost looks like something came up through the transfer port.
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Old 11-23-2012, 05:17 PM   #759
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Piston appears to be scored from one side to the other. Like it was too tight to the bore.
Or it got very hot very rapidly.

Was there coolant in the bike ?
Did you heat cycle it ?
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Old 11-23-2012, 05:18 PM   #760
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Did you drop something in the bottom when you were in there? Old circlip or something???
It almost looks like something came up through the transfer port.
Beat ya to it by 60 sec
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Old 11-23-2012, 05:22 PM   #761
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Beat ya to it by 60 sec
. At any rate, he might want to find a new mechanic.

Sorry, but that just shouldn't happen to a fresh rebuild.
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Old 11-23-2012, 06:27 PM   #762
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I've seen powerseal fix worse, that almost looks like a circlip came out but it's obviously still in there. Definitely check the bottom end out for loose parts.
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Old 11-23-2012, 06:30 PM   #763
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Thanks for the support...or lack there of.

The motor was not open for any length of time....only when working on it.

Nothing was dropped in there, as far as I know. No missing parts, clips, etc. Everything is accounted for.

There was coolant in bike. heat cycled, as as I did on the other rebuilds. Only other thing than the previous, those were done in heat of summer, and this was during colder, more recent weather.

Basically, I did nothing different than I did on previous top end rebuilds. Makes it that much more baffling.
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Old 11-23-2012, 07:45 PM   #764
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Quote:
Originally Posted by DougZ73 View Post
Yeah, looking at powerseal pricing now. looks like it will be a weld repair, rehone, and new nikasil coating.

I also just pryed rings off piston. Looked like they were lined up right and pins did not fall out or break off.

Still not sure what caused the really deep scratches.

Check with Lancourt. I had them weld a deep groove in a cylinder and replate.
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Old 11-26-2012, 04:55 AM   #765
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Is that plug gray ?
W brand piston ?
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