I hope i'm in the right place for this question, I wasn't sure! My big bore kit was a 96mm JE piston and a 94mm l.a. sleeve so the cylnder needed to be bored out to fit the sleeve and then the sleeve had to be bored for the 96mm piston. Its a little too late now, its installed and running but i have a question about the bore job? It was not perfectly true. At the bottom of the sleeve where the skirt comes out was not even??? One side was like a little thicker than a nickel and the other was a little thinner than a nickel? So the two pieces of the sleeve that extend out of the cylnder are differant thicknesses. The top looks good as far as spacing from the sleeve to the water jackets. so my question is is that normal to be slightly off or did they do a bad job? and the million dollar question is will it mess up anything from that being not exact?

Sounds like a bad, bad bore job. The cylinder has to be trued in the bore bar, before anything starts. From what you're describing, it wasn't in the bore bar true, and it was bored at an angle. Very slight, but still an angle. That's not acceptable for a bore job. That's a worker buying a customer a new sleeve.

That can cause some serious problems.

sh*t

Take that back to where you got it done and demand a new sleeve.

they might have jacked up the jug also, there no telling without a new sleeve.

Im not sure what to do man, its already together and running! Its only off by a little bit? im defenetly not happy but i have asked a lot of locals about it and im getting two diffrent stories. some say it will probily be ok and some say its going to cause problems! problem #1I didnt buy the sleeve from the guy that did the work! #2 a new sleeve = a sleeve, be bore, if he didnt mess up the jug, my time to tear it all back down, new gaskets, 2 more oil changes, Its getting expensive for me and i know they are not going to foot the bill for all of that. I don't know , it really burns me because i like having things done right!

You should at least talk to them. At least the owner of the shop and explain everything. I really dont know whats going to fail on you because I havent seen this problem before. I would "guess" that it could prematurly wear out crank bearings.

I think it must have moved between the cylnder bore and the sleeve bore!If it was at a bad angle from the start,the cylnder bore would be true with the sleeve, and both would be cocked going through the cylnder? am i right? If i leave it , what should i look for? Piston hitting the cylnder wall, lower bearings? The rings seem to have seated well by the butt dino and there is no smoke? man i really regret not going with the athena and a stroker!

Im just going to have to confront the guy and say what the hell! I just don't like asking, hey did you f up my cylnder when i don't have the engine experiance to say, bs this is not right? And when 3 locals say its probily ok and 3 say no, how do i disagree with them if they say its fine?

3 locals..NormalZ that posted earlier said absolutly NO. That guy has more knowledge about these quads than probably everyone on this site. Personally, I'd listen to him and NOT run it because its going to mess something up. Maybe he will chime in again and give you some things to throw at the guy who did it. From my little bit of knowledge if its off as much as you say then there is going to be a problem. You dont mess "rigg" with engine internals

Ok so i called him and asked why it was not even and he asked if it was the sleeve walls or just the grind that they put in so you can get the rings in? I dont know, i didnt look so, there is no way of knowing unless i tear it down again? now i have a nother issue, im going to start a new thread on the water pump!!! gr!

If i take it back apart, ill need a new base,and head gasket, that i know. do i need new rings and hone the steel sleeve again or is there a way to save the rings? Can i just pull the wrist pin and get new circle clips?

you just put on new topend gaskets? If so you can go to an autoparts store and near the RTV will be permatex coppercoating in an aerosol can. Use that and the topend gaskets should seal good as new.

And to save the rings just put the motor on TDC and gently pull up the jug until its just far enough up so you can take out the circlips and slide out the wrist pin. If you pull too hard you'll accidentally rip them out of the bore

just an update, thought the head gasket was shot after 8 hours of 210-235 deg. temps on this kit, took it apart and the water jacket warped and broke between the hole and sleeve. the install was sh*t in every way. It was slightly off center,the bore was off at the skirt by .020 and the cyl was over bored for the sleeve lip, leaving it too thin! now its a paper weight and i ordered all new stuff. As for this kit, I will never do a steel sleeve again. Im putting a cw 434 on it now.

I wish you would have posted up and asked what everyone thought about going with a sleeve kit. I'da told you they were junk. Spend the extra dough and get a real kit. I think normalz will agree with me on this. There are a couple people that have ran them with success, but the reason is because they had it bore and pressed in by a competent machinist. (which is hard to find these days) The success of the sleeve kit depends on how correct the job was done. I wouldnt even chance it. Sorry you had issues with it, but i would be bitchin at the shop who did your work and try to make them pay for your crap. go with a cylinder works kit and you'll be happy. prolly will run a lil better to because the cylinder will be at the correct angle.

I have had the Wisco BBK in my 03 and in my 04 for several years with no problems. But I did send the cylinders in to have the boring done. It's going to be tough to get them to fess-up about the w00ter-pore bore job. Unless they care about their reputation I think you're screwed. Good luck with your new setup.