After loosing compression on my DS and tearing it down I discovered that I have badly worn rings. (4mm ring end gap instead of 1mm recommended max in the shop manual.) Plus I have a pretty deep score near the top of the cylinder wall. I checked with the dealer and they want $626 for a jug, piston and ring kit.

I am thinking that I can have it bored and replace the piston and rings significantly cheaper and with as good or better performance. Can anyone recommend a source for parts and if there is someone who is greatly expierenced with mods on these cylinders???

Also any things I should consider that would be improvements in performance without a huge cost. I don't need to go too crazy on the modification as I expect to mostly trail ride and my stock DS is still the baddest machine in my group.

Thanks for any advice you have!

Jamie

 

Yep, I can recommend somebody....try hpresearch.net Im sure those good ole Kentucky boys can fix you right up...!

 

http://www.hpresearch.net/

 

Also, check with TheBom.

He should have lines on a slightly used 102mm bore and piston from one of his suppliers. I've seen the price on this set at $400 Euro so. . .
400X1.3 (to get to $$'s) X 1.15 (tax) + $75 shipping??? + his mark-up and you are looking at around $750??? That will get you a 680. Don't know what compression the piston is but, if higher than 11:1 you could have him modify it (shave the deck) for 11:1 compression so you can still run you 92 octane pump gas.

These guys may be able to do the work - has anyone used them? - They would just re-coat your jug.

There will probably be a few used jugs out there real soon now that HP Research is shipping the 105.5 jugs. You may want to post something on the What's in your garage thread.

 

Also can look in here.
http://www.tvipowerandsports.com/

http://www.rotax.net/

http://www.on-dunes.com/