Find a machine shop. I got mine rehoned for $15. Was going to send it to boretech to have it done (I think it's $60 there) and was going to get the carbide bore process but already putting so much $ into this thing I think I'll wait. After I got mine rehoned I also took it to a deburring shop and had it all bead blasted...has a real nice satin finish on the head and cover now. I also polished the right and left sides of the case. I'll post some pix soon.

If you are just having it re-honed, all you need to do is bring in the cylinder. Now if you were boring it, then you would need both the piston and cylinder.

You will only need to bore the cylinder if you are putting in a bigger piston. But first, is the cylinder in good shape? No deep scratches or gouges?

If the cylinder is still in good shape then yes, a re-hone should be all that is required for a new stock sized piston and rings.

As long as "what's going on" was brought up...Seattle and Pagan what years have you got?

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Then yes, all it needs is re-honed. It's a very simple procedure actually.

This is the type of cylinder hone I use typically referred to as a bottle brush hone.



It is the simplest to use. You just attach it into a drill, coat it with some oil, stick it into your cylinder and squeeze the trigger while you move it up and down. What the hone does is takes out the glaze caused by the piston rings as the engine is running and allows the new rings to seat properly.

When done you should have a bunch of minor scratches in a cross hatch pattern.

Does any of you know if Auto parts store can rehone motorcycle cylinder?

It's weird that 88pagan's 96 and mine 97 have the same issue.

Now I'm back to wondering..was it just a failure of the valve that did me in...or was it something I did?? hmmm, like valves out of adjustment, running hot, etc. I don't think either of those apply to my situation though. darn I really don't want to do all this work and drop another valve

Are you running the stock jet?

I was able to tune out the backfire by going slightly richer on the idle mixture and smoother running overall by going to 150