I purchased a 1998 KX80 with the engine disassembled due to piston failure. Upon trying to locate parts, I assumed it was standard because the previous owner was not real mechanically inclined. The new piston from "Wiseco" came in and is 1.75" approximately. The old piston is 2" approximately. Is this possible to have been bored this much over? I am being told this engine cannot even be bored at all only resleeved but it has not been sleeved. Is it possible that the piston and cylinder has been changed to a KX100 or bigger? How can I identify the piston? Numbers on the piston are "I16H6" then "2.00 MM" then "51P" then "CO". I need to buy a piston, rings, gaskets, etc. but don't know what to order from.

I have verified that the frame serial number is a 1998 KX80 and the engine block serial is KX080W......

 

Try this http://www.ronayers.com/fiche/frames...00&parent=7330

These are all OEM parts so if it has been bored out you will have to precisely measure and call for the correct sized pistons.
Keep us posted on your progress.

 

What are you referring to as OEM parts? The numbers that I described from the piston? If so, what are they out of? I was guessing a KX85 or KX100 or KX125 because of the larger size. The specific size of the old piston is 54 mm Is that a "stock" size? Supposedly, this cylinder cannot be bored.

If I cannot identify this piston, can you just ask for a specific size piston that fits a Kawasaki? The dealers in my area are not real helpful.

 

What are you referring to as OEM parts? The numbers that I described from the piston? If so, what are they out of? I was guessing a KX85 or KX100 or KX125 because of the larger size. The specific size of the old piston is 54 mm Is that a "stock" size? Supposedly, this cylinder cannot be bored.

If I cannot identify this piston, can you just ask for a specific size piston that fits a Kawasaki? The dealers in my area are not real helpful.

 

Not sure if that microfiche helped or not but the other bikes that you think the piston came out of are on there, maybe you can check the others till you find the right size.

 

Well, for anyone interested in this situation, I have found the solution although still not sure how it happened.

The cylinder measured out to be close to a KX100. The piston was identified by the middle numbers of an older Wiseco number (the outside numbers on each end had worn off so that is why no one could match the numbers).

What still does not make sense is how or why a KX100 cylinder is mounted on a KX80 engine block AND that the cylinder and piston were TWO sizes over stock on a cylinder that supposedly cannot be bored and had not been sleeved. The cylinder had a casting number that indicated an 80cc so it appears that the engine is a stock KX80 but.........

Don't know if anyone will ever encounter this but if so, I just ordered parts for a KX100 and everything went together great. It really screams too.

Thanks for the assistance.

 

Just file it in the "when you think you've seen it all" file. Glad it worked out and thanks for the update.

 

I am have the same issue bite me in the *** right now ..... wow thanks for posting all you updates