Good evening from sunny Durban, South Africa!

I am in the process of rebuilding a 1981 XV1000 that has been standing out in the African weather for 5 years, and have been informed by the Yamaha agents that the pistons and rings have been discontinued. I have however been able to get new big end bearings from Yamaha Japan.

I have thus decided to manufacture new sleeves for the existing pistons (original 95.00mm, good condition, with new rings), and I have some questions that I would like to put forth.

1. What would be the best material? - Thinking of GGG40 Cast Iron, or maybe AISI 4140 alloy steel?
2. Is there any specific procedures that I should know of?

I also want to use anealed copper rings for the head gaskets, as I have made those for various other bike engines, and it has been successful thus far.

Any thoughts regarding this *urgent* issue? ;D

First off: great plan and good choice of material.

Second: The pistons are still readily available, just not via Yamaha.  ;) Liners are available as off the shelf items that need some adaptations (i.e. trimming to size)

For pistons: Scheuerlein in Germany can supply them
for liners: Boston Liners in the US does liners to spec (and not really expensive)
for all the other small bits'n'bobs: CMSNL.com, e.g. for bearing shells but also the crankshaft ball bearings and the like.

Cheers,
Greg

Hello Bones,
welcome to the Comunity !

Check this out for your Piston and Pistonrings:
Scheuerlein.de
Link:
https://www.scheuerlein-motorentechnik.de/motorrad/yamaha/1000-1099-ccm/xv1000-tr1-81-86/

There you wll find, cmplete Sets in different oversize Values
Hope that helps you

Cheers Anja

Thank you all for the replies, I will certainly look into this.  [smiley=cool_3.gif] [smiley=cool_3.gif] [smiley=cool_3.gif]