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Nikasil cylinder problems HELP!

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 My ktm 105 sx cylinder is worn out!! This is the first rebuild this bike has ever had and there is under 40 hours on it. the bike has been trail ridden and i cant figure out what happened. we now have to ship my cylinder out to get recoated which ruins the dirtbike trip we where planning!!! we got the cylinder measured and according to the Manuel and the numbers he gave us the cylinder needs to be re coated. There are also a couple of score mark's on the cylinder!! i thought nikasil was supposed to last long???

 

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Yeah but if you let your piston get so loose it starts banging around in the hole that can shorten the life of the plating.  40 hours is a lot for a high strung 105 piston.

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Also, if the air filter isn't properly cleaned and installed, that can wreak havoc on the coating. In fact, there could be a number of things that would cause that. What did the piston look like?

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