In Feb 2011 I purchased this very clean Pilot. The origional owner said it was on the origional bore (but I am sure we have all been told that before). It only had 110 psi warm compression at 4500 elevation. We only took it out for 4 weekend trips last summer because I was worried about it but it ran great. This weekend we took off the top end to do an inspection. And holey sh** it is on the origional bore. The ring end gaps were past tolerence at .030. The service limit says .028 in the book. The cylinder looked great but I do feel midway down the sleeve a mico ripple but it is not enough to change the ring gap at any point. The crank looked great no visible rust or discoloration from heat and the rod felt tight in the up and down or twist movements. The crank bearings feel good at the cluch as well with no movment up and down or side to side and it spins well but I did not remove the clutch seal to check it out because they are not avalable and everything else looks so good. I am only going to do the top end at this time. I wish all of the used vehicles that I have boght in my life were in this good of condition. Pics below.

More pics.

This cylinder was marked B on the side of the reed cage area. I can still get the A Piston from Honda which is a little bit bigger and hone the cylinder to fit the bigger piston. Do you think this is a bad idea? Should I just bore it? One more question is the Honda .25 over piston bigger or smaller than the wiseco 80.5 piston?

I cannot answer about the first question, but i beleive the honda .25 over piston is only 80.25mm vs the 80.5 wiseco.

I scored on all the stuff to do factory Honda .25 over top end except the oem wrist pin bearing. I do have a wiseco though. Does anyone think the wiseco wristpin bearing is less quailty than the OEM?

That color cylinder gasket is usually a indication of factory gasket gaskets sold to dealers were green not blue.

I am in Florida for about another week or I would say send it to me I will hone measure the cylinder then we could see if you can use the stock bore again.

A ridged hones needs used to hone that cylinder any type of flex hone will hide any unusual wear patterns. Wear patterns examples can be found in these threads, not sure if you seen any examples in the past so here are a few
viewtopic.php?f=24&t=5479
viewtopic.php?f=30&t=2404
viewtopic.php?f=1&t=2366

Hoser,

Sounds good. Just let me know when you get back.

Thanks, Michael

I could not get the rings for the standard bore from anywhere even though the piston is still available so I did go ahead and get the .25 over.

Try to get the same bore OEM rings for a FL350 they will work, another words a 80mm FL350 and a 80mm Pilot are the same ring different number, also check with that guy in the UK he might have some, forget his nickname here he just sent scPilot66 a set.

I will check around after you check the cylinder because I am a little short on cash right now after buying the other piston and it might not be able to be used on the STD bore anyway.

Thanks again, Michael

Hoser I sent you a PM. Hope you had a nice time in Florida.

Hoser did you get my PM?

Check your PM's

Hoser,

I have a question about porting. Should I even port my cylinder if I am going to use the stock pipe and silencer. I am already going to a speed head w/ 49cc dome and have the 88 Cr250r reed cage and stuffer w/ boysen power reeds. Also planning on using a PWK 35mm airstriker carb. I don't want to cause a problem with my Engine do to restriction of the pipe. I am not looking to race my pilot and I do have a young girl driving it as well. I also know that riding style has an effect on the way a Engine should be set up.

Also I may have to increase the compression with the 47cc dome if the 49cc is not enough because we ride mostly at 6000 elevation. and only down to 4500 an rare occations.

Hoser sent you a PM.

I don't "port" engines or cylinders I 'hoser enhance' Pilot and Odyssey cylinders, I would never call the work I do porting because it would be a insult to Engine builders who does it for a living.

So what do I do, I make changes to the cylinder and its design that has proven to make more power and and still is reliable, it makes more power from bottom to top and easy to tune and maintain the tune.

The changes I make to the cylinder will increase HP and torque over the stock cylinder with about any combination of carb and pipe you use you will see a noticeable difference in the stock cylinder over hoser enhanced version.

To take full advantage of my work I suggest a aftermarket clutch, a power pros REV pipe, a 39mm PWK carb, dual inlet mod to the air box, and a Speedchaser head, his heads has increased cooling , more rigidity to prevent head gasket failures, more performance.

Feel free to ask in private or in public others who has a hoser enhanced Pilot cylinder see what they think they also can give you feed back what other modifications they have done to go along with my cylinder enhancements.

Your stock pipe and silencer will definitely be a limiting factor in your setup you planning on installing a after market pipe in the near future or you going to stick with the stock pipe?

I am going to get a power pros rev pipe in the future but I just want to make sure that I wont be harming the Engine in the time being with the stock pipe because I will not be able to get the pipe for a while as money is tight. Maybe not even until next yr. I do have a speed head that I will be putting on with this build. I have a modified airbox it is not dual inlet just a larger 3" inlet tube with a prefilter and a uni in the airbox. I still have the stock carb on it. I am going to put a 35mm Airstriker that I have laying around on it. Should I wait on the carb until I get a pipe?

All the go faster goodies for a Pilot are expensive when I bought my Pilot it was all stock and I had to bump up the power a little at a time as funds allowed, first was the clutch/air box mod then was the "porting" done by a friend of mine then later by MacDizzy then further refined by myself, then the 39mm PWK then the pipe and then the rev limiter mod to the CDI (Capacitor Discharge Ignition), cool head, cost adds up fast.

hoserizing or porting the cylinder on a all stock Pilot wont harm a thing and you will notice more power but to take full advantage of the modified cylinder and head you need the rest of the stuff I listed above.

If your the buy and try guy with limited funds get the pipe install try then the next time you tear down your top end for inspection send it out for hoserizing or porting you will see feel the difference

Not really the buy and try guy. Just did not want to stress my Engine. I did Pm you that I shipped the cylinder on last Monday and it could be there as early as Monday. Please let me know when you get it. Thanks.

Hoser,

You have probably got the cylinder by now. Please let me know if everything was ok. By the way I sent you some stickers. Hope you enjoy. I forgot to send the exhaust manifold. Do you need it ASAP?

Michael

Got the cylinder back from Hoser. Very nice job. We were able to put it together today.

Last year Sommer learned how to build a 4-stroke Engine. This year she is helping with this 2-stroke top end rebuild. She was interested in learning and doing everything except the pre-lubing with the 2-stroke oil(yuck). Can you say girly-girl? And did you see how she dressed for the job?

We still are only getting 130 PSI static compression with the 49cc dome at 4500 elevation. I know that it is not broken in yet but I don't think that it will go up that much. Want to get your oppinions. Should we go with the 47cc dome from speed because we usually ride between 4500 and 6000 elevation? And going up to 6000 elevation dropped us about 12 PSI before this build. The squish is .045"-.046" with the old stock gasket with all the black coating scraped off. We checked the squish with the solder attached to the piston to make sure of the reading. As it is I don't think that we can use just one layer of the gasket.

Yeah try a 47cc dome, do you have one ?

No. Will have to talk to speed.

I will look to see if I have a 47cc dome if I do I will send you can try it see what you think, if you like you can either send me your 49cc or another 47cc ?

Pretty sure I had Speedchaser cut me a 47cc I doubt I will ever use it.