Plated Cylinders

[hughes]

My 87 KX500 has a plated cylinder. I removed the cylinder for new top end rebuild and noticed there is zero cross-hatch present. The engine has always ran strong and is a bear to kick over(I never checked the compression with a gauge). Is cross-hatch suppost to be present or is there low micron pores that retain the oil(texture of the plating) Thanks

[doordie]

hughes,

A pic will tell us more if you can post one.
But usually, if it?s used/worn cylinder no cross-hatch will be remaind.

//doordie

[04kx500]

NO! YOU SHOULD NOT SEE CROSS-HATCH IN CYCLINDER,YOU DONT WANT TO  SEE IT ON YOUR CHROME BUMPER OR YOUR CHROME CYCLINDER.MOST PEOPLE THINK YOU SHOULD GO HONE CRAZY EVERY TIME YOU HAVE IT APART, WRONG YOU WANT TO HONE AS LITTLE AS POSSIBLE TO SOFTEN ANY ROUGH SPOTS FOR NEW RINGS.mY 2004 KX500 HAD NO VISIBLE CROSS HATCH AFTER 4 HRS. i KNOW CAUSE I BORE BLOCKS

ERIC-04KX500  GREATENGINES.COM

[hughes]

So I guess the small micron pores in the plating retain the oil . The plateing looks good no flaking of scroing around any of the port openings. Maybe best thing is to measure bore and then install new top end. Like I said before this thing runs like a rapped ape The only reason for the new top end at this point is so I know what I have. I am slowly restoring this thing. I am use to looking at marine(Outboards) engine with cast iron sleeves which require cross-hatch :waving:  .Thanks

[Rowdy-Yates]

AHHHHHHHHHH  help me out here but I just read to hone the cylinder. You are not suppose to hone plated cylinders. You will hone the plateing off. Call me crazy but I think I  am correct here.

[hughes]

Rowdy-Yates,

Everything I have read on the net says that their are small micron pores in the plating that retain the oil. I agree with 04kx500 about light honing just for repairing cylinder. But that's just my opinion. Thanks

[kawdude]

I have heard both arguments for why you should hone and not hone.  EG honed my cylinder after he bored it and if does it I would say it's best.  In my opinion honing must be done to seat the rings.

[hughes]

When you had your's bored is it still a plated cylinder or a sleeve

[04kx500]

ok, i was unclear in my statement. Should you hone a plated cylinder? NO! UNLESS you have some type of scoring on wall and you cant afford a replate at that time.To go by the book,any scoring or flaking ,yes ANY really constiutes a replate.This is a " make do " situation for some one who hopes to get a little more life on that cylinder.Honing the plating is doing DAMAGE to the rings and cylinder both ,but will buy you some time.

[gowen]

BE VERY CAREFUL HONING A PLATED CYLINDER! I would only (not really but what the hell) hone if there are light scratches, burnt oil, or minor aluminum scuffs. If the scratches, major aluminum scuffs or chipping exists, replate! Anyway! If you chose to hone, use a ball hone only. I've been told and read you should only do it with a diameter that is somewhere around 10% smaller than the cylinder bore size. NEVER USE A THREE STONE honer, it will mess the port edges up.

Yes! The cross hatch is good for a new cylinder (if you keep your current piston, do not worry as the cross hatch is good for getting oil to the piston breaking in!)! If you have factory plating, replate it, cause on a '87 it will more than likely chip when honed. Just remember to coat the cylinder in oil. Use a ball hone 240-360 grit alumnum oxyde material, that will ensure you do not take any plating off, if not loose.

I also had my Cylinder bored by Gorr and it was replated, I'm sure Kawdude's was the same.

[hughes]

doordie and others.I posted some pictures in my gallery of my cylinder need to know if I could get some more use out of it. Just laid down over $500.00 in parts this week and just don't know if I could spend anymore. Tell me what you think. a.huhges 87 kx500 gallery first page. Bore size 86.02-86.35 10% smaller for a ball hone would be 77.67 is my math right Thanks

[John]

I was curious about this and checked out the official service manual; "..the cylinder must be replaced with a new one since the ELECTROFUSION cylinder cannot be bored or honed" This quote is taken from the section of how to inspect the cylinder wear. It is however the only reference I find to honing in the manual.

I think that's a clear - but not entirly correct - statement since you can replate the cylinder.

//John

[hughes]

John, What manual? Cylmer or Kasawaski. They might be talking about honing a cylinder to square it up. I think when they replate they go in with a cutting hone to square the bore up with the center line. But i agree with you about clear and unclear statment.

[John]

Hughes,

That would be the Kawasaki Heavy Industries LTD Motorcycle Service Maual from 1988 - part no. 99924-1101-01

It might be a tad old and outdated. Really, 1988, my kids are yonger than this book!

//John

[John]

At least the language is modern-ish "Thau shall lubricatum thier bearings.." etc.