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1986 KDX80 Bore

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Hi there,

This is a question for a friend who is planning on boring his KDX80 cylinder from 48mm to 48.5mm and then rebuilding the engine from there. When reading through a service manual it says that ELECTRO FUSION cylinders can not be re-bored. How do we know if this bike has an ELECTRO FUSION cylinder?

Thanks

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They all have plated cylinders.  You send them off for replating to standard size and they remain at 48mm.

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2 hours ago, turbo dan said:

They all have plated cylinders.  You send them off for replating to standard size and they remain at 48mm.

Thanks for that info, unofrtunately in NZ it will cost too much to be able to make it worth doing so will have to leave the bike for parts...Cheers

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As delivered from the dealer (NEW) it came with a plated cylinder. Who knows what was done in the last 30+ years to that cylinder? You! :) If you want us to know, a picture is worth a thousand words. It may have had a steel sleeve installed at some point in its life. Look around the internet for sleeved cylinder pictures vs. plated. Kawasaki's trade name for their plating process on the KDX's is called Electrofusion. It indeed SHOULD NOT be attempted to hone it! A plated cylinder that is damaged can be repaired and replated or a sleeve can be installed.

 

Please post a picture of the bottom of the cylinder with great light that shines well down inside the cylinder.

 

If the cylinder has been sleeved and any gouge or damage is not too deep, then it can be bored to the next size of oversize piston, then honed and new piston / rings installed.

 

Here's a pic of a sleeved KDX200:

 

http://i1239.photobucket.com/albums/ff515/actionman1972/Mobile Uploads/20150412_214245.jpg

 

Here is a picture of a cylinder bored to take the sleeve.

 

img_0900.jpg

Edited by KDXGarage

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That's plated.  Or it used to be.  I've never seen one so far gone.  They got their moneys worth out of that one, no doubt.

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WOW!!! That is the worst one I have ever seen that is from use and not catastrophic failure.

 

That appears to have a little bit of the original plating still on it. It needs to be replated or sleeved.

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