So I got the top end off the KLX and the base gasket left behind some crud stuck to the case. What do you guys do to remove that without any of it falling into the hole? I was just thinking I get out a razor blade and carefully skin it off there little by little.

 

Stuff the whole with a rag and use a scotch brite pad and some carb cleaner if needed. It will come off very easily. You can use a razor blade, but the aluminum is very soft and will score easily.

 

Thanks. I'll give that a shot.

 

No big deal. I took the big stuff off with the razor blade and cleaned it up with a scotchbrite pad.

 

Well, my KLX250 is now a 300. Now for the suspension.

 

Could we please have a before and after report?
David

 

Man, there's so much little stuff I'm doing to it and there's so much time between me riding it this last fall to riding it again this spring that I don't know how I can do it. Well now, my friend has a red '09 with a pumper carb, Power Bomb, Q4, Unifilter, and no snorkel. We'll have basically the same bike except I'm 8mm larger on the bore. I can ride those side-by-side and get a comparison.

With this thing, we honed it just enough to put fresh cross-hatching on it and took all the old lines from the prior rings seating. It was still .0035" clearance after doing that so I figure we're in good shape. I gave the piston 2 treatments of Piston Kote to give it a little more lubricity. The rings gaped in at around .013-.015 so I didn't need to do anything to them but debur the ends.

I will say this though. The steel sleeve in the new jug had supposedly just a few hours on it and you could already see it wanting to glaze up in spots. See, I don't know if he just threw in a new set of rings and didn't break the glaze with a hone on an old bore or what. Why was he parting-out a bike he just rebuilt after 3 hours of use? You know what I mean? I wonder if he dropped something down the hole like a circlip and thought he'll just let the bottom end eat it. Anyway, my 250 bore has a lot more than 3 hours on it, more like 1300 miles, at least 500 of which are through the woods, and that Nikasil bore is immaculate. If I do this again, that's what I'm going with hands down.