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And after getting it this far.I think i have the piston in backwards.The arrow should face the exhaust port...right? No harm done.

Cylinder is back from getting a new nikasil liner. All clean ready to install piston. Lubed up ready for a worry free break in.Note the second base gasket. Cylinder lubed the same. Nice easy install. The dots will keep track of how far the cylinder bolts move to achieve 25Nm torque.The last bolt under the coolant pipe can't be reached with the wrench.I turned the last one the same amount. Couldn't find an extra long T45.I cut the "L" off a torx wrench and welded a nut on it.Cheap and works well.

The swingarm bushings needed to be removed for black powdercoat.A suitable sized socket and hammer did the trick.(thanks Jason)

Bought the kit at my local Ossa dealer.http://dualsportplus.com/

It's not easy being green.

I have put my Ducati track bike into storage to ride trials because of the expensive weekends at the track.Casual trials competition is cheap.

Here is a pic of the piston.It came apart for inspection and to install a second base gasket.The engine was running perfectly!

The damage was at the intake.I think it was just rough use and maybe a bit too tight.(it's a 2011) I trust CV-Tech know what they are doing.My dealer sent them the factory specs.The piston is a oem 75.95 which is the A.I don't know what the clearances are.Sorry. The picture doesn't show the radius work they did.Here's a pic that does.It's really well done.

Had my Ossa's nikasil cylinder redone by this Quebec company.Cylinder looks better than new.Prompt friendly communication dealing with the clearances needed.$300 (cdn) is better than a new cylinder for sure.I sent them the new piston and buggered cylinder and they came back in 3 weeks. http://www.cvtech-aab.com/en/ Before After

Got some parts.

Anyone know the piston to cylinder wall clearance spec? The ring end gap as well.Searched everywhere and can't find it.CVTech in Quebec needs the numbers to redo the nikasil liner.

Thanks for the tips kt-milley. The frame is finally ready for powdercoat.Just a little pressure washing to be done.

Finally have the frame totally stripped.Getting the fuel pump etc out is a bit tricky.My coworker loaned me a Mactool fuel line tool set that made the job really easy.It would be very tough without it.I'll cross reference the fuel filter for a replacement.

Thanks Digga.I'll try it.

WTF! A bolt on both sides of a pivot? How the heck are ya supposed to get these out? Last thing to remove before the frame powdercoat. Grrrrr!

I use a syringe from the pharmacy.Very accurate.

The intake is spotless.I'm not gonna get my panties in a bunch trying to figure out why...it's a two stroke,it happens,i'll just fix it.

Thanks Digga.My 2011 air filter is original.

I wish I knew what filter cage you two are talking about?

Had to make a wrist pin tool from a piece of pipe,washers and threaded rod,but now the piston is off.Really cool bunch of engineering has gone into the cranckcase of this engine.The big end bearing of the rod feels fine.i don't see any debris of any kind in the crankcase.I really need to build a proper workbench.

What filter cage?There is nothing in mine.The big end feels ok.I'll know better when I get the piston off.The piston is a nice ash tray now.

I will run 100/1 from now on I think.Spark plugs are cheap.Yes,it's the intake side.I'm going to have a real good look in the crackcase (as best as I can) for any dbris.It does look like foreign matter.I'm very fussy about cleanliness during filter cleaning.I thought the exhaust side was more prone too. This is the exhaust side.

The piston material should come off with some acid.Doesn't look as bad as the pic.Most of the dark stuff just wipes off.I'll have to measure it and see if it's out of round.I know where I can get an almost new barrel tho.It was running so good!!??

It's a 944 retired Battle of the Twins racebike. 140/1 as per Ossa Canada

This was supposed to be a "cosmetic" makeover.NOT ANYMORE!!!!!! GRRRRR!!!!!