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Rev 80 Top End Rebuild

rev_80_brothers
in Beta

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I have just bought my eldest son a 2007 Rev 80, and by my standards the top end is noisy. I bought a second 2003 Rev 80 for my youngest which is positively silent by comparison!

A couple of questions:

1. Are there differing piston sizes/tolerances (like MX bikes), or is there just the one size? If there are various sizes, how do I know which to buy? Is there a mark on the cylinder anywhere?

2. Are the base gaskets of differing thicknesses (like KTM/Yamaha) and if so, how do you know which one to buy?

3. Where can I get a workshop manual (or even better download)?

I used to compete in Enduro on KTMs and they were very straightforward. The trials bike rebuilding is slightly new to me!

Thanks

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