[Screamer]

I have a 95 cu. in. kit in my bike now with 93,000 miles on it. I want to rebuild it and was wandering if I can bore out these cylinders to 96"? Will the heads still work OK? Is this not a good idea?

[ReeseSS]

They make 5,10, and 20 over pistons so you can clean up the cylinders if they have a lot of miles and put in the new pistions, what that would take you to as fars additional displacement, you would have to do the math. There is a kit out there with new cylinders and custom pistons for a 88 that increases the cubes to 98. I will do some digging and get the web site for you. There seems to be a lot of confusion out there when they started making the 96" TC, not saying this is the case here, How it got it's extra 8 cubes over the 88 was increasing the stroke on the crank from 4.00 to 4.38. The diameter of the pistons and bore of the cylinders are the same (3.75 ) as the stock 88.
The web site for the 98 kit is www.gmrperformance.com

[kenfuzed]

There's only enough material to go 95" + 20 over in cleanup, but not enough for 96". Another alternative is to pick up a fresh set of cylinders from an 88 or 96 (same size) and bore them out to 95". I picked up my last set off of ebay for cheap. There's also some guys on there that sell them already bored to 95" and ready to button up.

I might have a set I'd part with that have less than 2k miles on them when they were pulled off an 05 TC88.

[Screamer]

Thanks for the help, I'm trying to contact GMR now.

[hotroadking]

If you are rebuilding it, I would bore it a bit over and change the flywheels to HD 103 or S&S 106, you can use the same bore, new pistons and rings which you should do with the rebuild anyway, this would really upgrade the motor.

Get the PN and check with Jenny at BenjyHD for 20% off or order the hd flywheels from Zanotti or Chicago HD at 20% off.

[whacker]

Thought I would throw in a question here...At what point would you have the motor balanced??I put new heavy duty S&S rods in my bike and had the motor balanced at the same time.

[REED]

Check out Revolution Performance their kits are reasonable and use no iron liners the liners are new technology Nikasil same as if you race an F1 car or get in a new porsche or many of the high output 2 stroke supercross bikes. They even have new heads roller tip rockers pushrods lifters and cam kits and their prices are very competitive Tom

[ray587]

you do not want nikasil jugs! bmw and jaguar stop using this process years ago because the sulfur content in some gasolines will eat the nikasil lining away. on 2 stroke engines this isn't much of a problem because the oil helps coat the cylinder.

[Screamer]

Thanks for the information, I purchased a set of 95" jugs with Keith Black pistons and I have a new set of stock heads that I'm going back with for now. If the engine sounds good after this rebuild, I'll have the heads ported and be done with it.
Thanks again for all of the in put.

[kenfuzed]

You should be quite happy with those Keith Black pistons. Just make sure you check the clearance when installing since KB's are made to fit tighter than SE's.

[REED]

Ray 587 this is the first thing I have ever heard of sulphur in fuels bothering nikasil liners, you think it would bother cast iron liners more as iron is one of the elements most subject to corrosion from anything and the only thing you could get from sulphur in fuel would be a mild mix with water to make sulphuric acid.
Not much sulphur in gasoline they even have the diesel fuel dow to 5 parts per million now so I don't know where one coulde find any fuel with greater than that and I sure don't burn diesel in my motorcycle. Tom

[ray587]

i own a 1998 xj8 jaguar that had nickasil plated cylinders. the engine was replaced under warranty because of this. bmw had a similar problem. they all have alusil now. the gas now may have less sulfur in it than in 1998. go to any jaguar or bmw forum and this is widely discussed.

[REED]

I haver since read the info on the forums and it appears that this was mainly in Europe where poorer fuels were prevalent. It should be noted that BMW has been using nikasil in their boxer twins for decades with no problems, also note that several of the highest performance v twins available use nikasil eg Ultima and if you check guess who does their nikasil plating. Also note that the chev Vega engine used an alusil like process for their engines and if you lived in the southern states some did extremely well but those we got here in canada really didn't do well and after about 3 years of age all were either sleeved at the owners expense or as I discovered they made one helol of a car with a 302 or 350 V8 which is what the car was really designed to have in the first place. Their alusil blocks and iron flash coated pistons really didn't hold up. I think nikasil with todays fuels and maintenance should be the ultimate bore material, it is definitely time for new technology. tom