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?

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