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Old 04-12-2014, 05:24 AM   #1
Queen of Spades OP
tall drink of water
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Joined: Mar 2009
Location: Decatur, GA
Oddometer: 692
Two-stroke cylinder repair - what's needed?

Rebuilding a 89 kx125. The cylinder is missing a stud and powervalves are frozen tight. Cylinder itself looks like it is in decent shape aside from powervalve issue.

1) Is it best practice to replate an old cylinder even if it looks kosher?

2) What usually causes powervalves to freeze up and how are they unstuck and returned to serviceable condition?

3) Can cylinder studs be helicoiled or is that asking for trouble?

4) What should I expect to pay to have #2 and #3 done if I sent off to Millennium or elsewhere?
'99 KTM 640 LC4 Enduro (January 2014 snow ride)
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