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Don't trust either eBay's or Amazons compatibility list. They are right as much as they are wrong.

You can and should hone either type type of cylinder if replacing the rings. There is generally a hone, either ball or bar or flap etc. that is made for lined cylinders. The surface is harder in a lined cylinder so if you use a hone for a lined cylinder in an unlined cylinder it will cut faster as there is usually diamond dust or another very hard crystal on it. With a light fast hand you can get away with using it on raw steel or iron. At least so I've been told and seen done first hand without issue but the guy, my buddy rebuilds engines every day all day and has an eye for doing it.


For two stroke cylinders that have ports and nikasil or chrome a flap hone with diamond dust is a better choice as it is less likley that it will "peel-up" the plating at the edge of the ports.. lots of variables. Always research and ask those who have done many if you have access.
 
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Discussion Starter #44 (Edited)
Top end rebuild completed......Success!

We replaced the rings and honed the cylinder. Fresh gaskets and gasket maker again. Weird thing is that after we used an internal micrometer to measure the cylinder and calculate rind end gap, the new rings gaps were a little larger then needed. According to the clymber manual the cylinder was still in spec for the current piston. So no filing needed (shrug). But the cherry on top is we took a 6 hour road trip last week to pick up an older model red shock that's fully adjustable and installed it before the engine was put back in. The shock is a huge improvement.

After some short runs and cool downs we took it up and down the gears for 20 mins and called it a day. A few short bursts of smoke that could be related to old gunk in the muffler or assembly oil. Other then that it ran smooth and clean.

Awesome! It feels good to be the extra hands and researcher in this project giving me more confidence to work on my TW when the time comes. Plus I get my riding partner back on a 200 for the rest of the summer!:) Thank you so much for the great advice and support.

200s.jpg
 

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Looks good. My XT200 is under sprung suspension wise and no noticeable advantage in HP because they are basically the same engine with different tranny (mechanical one) but being about 50 pounds lighter it's a hoot sometimes, i.e. more nimble. Still, when I get back on the TW I feel more confident and stable. Kind of like a bull in a china shop. Charge vs. tip-toe through the tulips. Fun in each their own way. I'm sure your gonna feel the same about the XR vs. TW. Like me, you'll probably still like them both.

 

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Discussion Starter #46
Thanks Admiral

I agree that it looks much better now. It's bored 1mm oversized and only a few more CCs resulting, but it is way peppier. Part of that being lower weight and part gearing. It's not easy to keep up with but I'm not far behind. Maybe if I traded the battery for a capacitor and swopped out the tank for a plastic one, but TW tires are too wide to accelerate too quickly or reach too high of speed offroad.. Spur them on all you want but each beast is only as capable as they're bred to be.

The rear suspension is much better now, so at the very least we'll redo the front end with fork oil and at least add spacers to balance out the front end. That is if we have difficulty finding the right springs.
 
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