Question about 2002 Suzuki DR-Z 250

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I have 2002 dr z 250 can the cylinder be bored out, or do just replace with new.

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Yes the cylinder can be bored, BUT, it would be sent to a company in California for the work. The cylinder has a nickel plated surface that will be destroyed by the bore job. After the boring is done they re-plate the cylinder and send back a new oversize piston and rings along with the re-plated cylinder. The cost is around $400. It will take about 3 weeks to get the cylinder back.

A brand new cylinder will cost around $420, piston $48 and rings $35 for a total of just over $500. The time needed will be depending on whether or not your dealer has the parts on hand. Please rate my answer. Thanks.

Posted on Aug 24, 2010

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1 Answer

Standard bore size mm


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Mar 15, 2014 | 1999 Daewoo Lanos

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Hi my name is Jas I have an 1989 Ktm 250 I have blow the piston and rings and have damaged the cylinder inside I'm wondering if you know how I repair the cylinder? Does it need to be re- sleeved? Or...


i would look into boring it out but bdepends how bad cylinder is damaged.... maybe buy a replacement cylinder head as it would be cheaper.... hope this helps

Feb 28, 2011 | KTM MXC 250 Motorcycles

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Hi I am doing a simpile head & cylinder inspection. Just bought the bike smoking bad. The cylinder & piston are damaged. I will be replacing piston rings & doing a bore job to match new piston....


The diagram below should work for you. Put the piston on TDC. the OHC cam gear will have a single mark or may have two marks, see below. Be certain the front side of the chain is taut when mounting the gear. The cam chain tensioner keeps the back side taut.

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May 24, 2010 | 2002 Yamaha TT-R 250

1 Answer

Is there a coating on cylinder of my 01 kx 250 that wears off to make the cylinder usless


Yes, that is a plated cylinder so if it galls, or wears out, it cannot be bored out you have to put a new sleeve in it. The new sleeve will be able to be bored out so it will last for a long time. The resleeving is best left to a cycle shop or machine shop with the propper equipment, as it is an interfearence fit and the cylinder must be bored perfectly, then heated in an oven to be able to install the new sleeve.

Apr 18, 2010 | kawasaki KX 250 Motorcycles

1 Answer

Can you bore a sleeved cylinder from a standard 1991 Kawasaki kx 250 or will it need to be re-sleeved? Not sure if the cylinder sleeve is stock. My understanding is that Kawasaki installed factory sleeves...


If you say it is definately sleeved it should be possible to bore it, you normally get one or two oversizes before it needs resleeving. If you are able to buy an over size piston from kawa or wiseco, chances are it can be bored.

Apr 16, 2010 | 2003 kawasaki KX 250

2 Answers

My cylinder got gouged by the piston. Can I bore


It depends on how deep the gouge is. Having it bored and a new oversized piston may set you back more than a new stock piston and cylinder.

Oct 26, 2009 | 2005 Honda CRF 250 R

1 Answer

List of all components for a top end rebuild. Is there a kit out there?


  1. Piston
  2. piston rings
  3. head gasket
  4. Cylinder base gasket
  5. Fresh bore on cylinder (if it can be bored), see note
  6. Possibly valves, valve guides and valve seals, see note
  7. Miscellaneous seals and gaskets
NOTE; some cylinders are nickle plated and can not be bored unless re-plated. If cylinder is beyond repair then replace it. The valves should be re-seated. If any dishing or valve stretch is present, the bad valves must be replaced. Valve guides seldom need replaced but valve guide seals could be bad. If the bike gives a puff of white smoke when started after sitting for 5 or 10 minutes then replace the seals.

A “very helpful” rating on this answer? Thanks!

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Jul 02, 2009 | 2003 Yamaha WR 250 F

1 Answer

Bore size


The cylinder bore is just that > the bore size of the cylinder. The piston clearance should be 0.0015 to 0.003. Anything more than .005 and the piston is too loose.

Apr 17, 2009 | 2003 kawasaki KX 250

2 Answers

CR 250 2001 keep cracking piston?


Look at the piston. Is there an arrow mark on the top of it? The arrow should point towards the front of the cylinder. Although the cylinder bore is round, the piston is mildly egg shaped. this allows for expansion. The piston may have been mounted incorrectly.

Other than defective pistons, the only thing else I can think of would be pre-ignition putting stress on the piston. Go to premium gas and a stock spark plug.

Mar 23, 2009 | 2002 Honda CR 250 R

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