Hmm, sounds like a good opportunity to have the biggest bore klx available, even if not by much. I would venture you just had some bad luck with the bearing. Piston/sleave wear look like its from lateral play in the rod?

 

The saga continues-spoke to Vince @ Mr. Crankshaft today. He was able to disassemble the crank and he said that the crank pin and cage were in relatively good shape but the needle bearings were heavily pitted. The biggest issue is the ID of the big end of the rod, specifically the thrust side of the rod has worn about 1 mm. He said that it almost looks like the rod may not have been properly heat treated and that may have caused the wear issues. Just my luck...After making measurements of the rod and searching through available replacement parts, nothing available is close so a new crank is on the way.
Also spoke to Bill, he attempted to hone then cylinder to .010 over and it won't clean up so a new sleeve is the only option. I really appreciate the effort Bill is making to help me out and guys like him are the reason any business succeeds-standing behind his work.
Hopefully the parts will be in next week so I can get this thing back together and get back out in the woods again.
P.S.-the Web Cams 101's are on the way...seemed like as good an excuse as any to do it.

 

Well that stinks, but at least your gonna have it going again soon.

Let us know how the webcams work out.... been eyeing a set myself.

 

yeah what he said

 

Sounds like a good news/bad news deal...Web Cams to ease the pain.

 

Update- the bearings and seals are here as well as the new CCT. The new crank should be here on Monday and just got an email from Bill tha the cylinder/piston has shipped and should also be here on Monday. I spoke to Debbie @ Webcams and the 101's should be going out next week.
I just finished installing a water pump and timing belt on a Pathfinder(lots of fun) so I have to get my shop organized before I start to prep and assemble the cases and bottom end. I decided to lap the valve seats and de-carbon the head while I have everything apart.
If all goes well I should be hitting the woods in a couple of weeks...to be continued.

 

New crank and balancer bearings are installed. Did the ' heat the cases in the oven and put the bearings in the freezer' routine. I expected some resistance installing the new crank in the l/h case half but the temp difference allowed everything to just slide together. I'll start to install the rest of the guts tomorrow and mock up the piston/cylinder so that I can get an idea of the compression ratio.
I did some searching for some info of head volume but I couldn't see anything so I cc'd the chamber and I come up with 19cc-does that sound about right? I'm shooting for mid 12's-that should work a bit better with the longer duration of the new cams. I keep my laptop handy so that I can verify that I'm putting all of the parts back where they should be.

 

Gettin' interesting.

 

No update!!!

Man, Im anxiously awaiting the news on the cams!!

 

Finished buttoning up the bottom end today. I'll mock up the cylinder to get an idea of the deck height so I can adjust compression ratio. Webcam shipped my parts out today so it will be next Tuesday before they get here. I'm still amazed that this thing toasted the rod bearing-everything else in the engine is pristine. Aside from pressing off the old main bearings this engine is amazingly easy to work on-at least it is when it's on the bench...