The Cylinder wall was glazed with no hash marks visible for the rings to seat well against
 

I used a three stone hone by hand with cutting oil to remove the glazing and re-introduce the hash marks
 
Standard Bore was 70mm, mine measures 70.015mm. Ring gap is to be between .2-.4mm mine both measure .2mm.

Oiled everything up and reinstalled the cylinder and torqued the head down to 30' lbs
 

With the Cylinder and Head back on I reinstalled the Autolube pump hose to the Cylinder with two new Fiber Gaskets then moved to the Intake side
 

New Gaskets on both sides of the Reed Block, torqued those four bolts to 19" lbs and put in a new Intake Manifold Gasket. The Carb already had a new O-ring fitted between it and the Intake Manifold.
 

I'd purchased a new Yamaha Air Filter last year, cleaned and re-oiled it. The boot between the Air Box and Carb was also replaced last year. The Exhaust Gasket was replaced last year and the Gasket/Packing that goes in the Exhaust Manifold slot the pipe fits into was installed.
 

Lastly the Exhaust Manifold and Pipe were put back on
 

Oh, here's what the Head looks like with the carbon off it
 

Bike is looking good. I'm no expert & do a lot of guessing but as a lot of heat had been getting down past the rings due to stuck in the grooves i't be a good idea to fit new rings "just because". End gap isn't super important but what is important is wear on the rings where there go up & down past the ports. Good idea to insert each ring down the bore a bit, "& individualy", about halfway between top & cylinder & the ports & end gap exactly in line with the ring peg for the particular ring. Then hold it up to the light & look for daylight past each ring at points around the ring--exhaust being the biggest port. Or just fit new rings & don't worry. New rings will likely have more tension as well so win-win.
If i'm not reading the story back far enough then ignore my woffling.

Kinda' too late RT325, the cylinder's back on. Next time I pull it I'll most likely plan on replacing the piston and rings.

Just received a text from the owner of the body shop I've got my parts at. He stated the color and vinyl's on, now on to clear. I asked him to burry the vinyl in the clear to not be able to feel an edge.

Got my painted parts back today. I, and the painter said a 9.5 out of 10 color match. I'm happy.












The sun's a bit harsh out right now, but the color match is damn near spot on!

The paint looks fantastic! They did a really good job... My fuel tank is original but my oil tank I had to paint, I used the House of Kolor sunset orange pearl and my old eyes can't tell the difference. Wish I could post a picture... Your bike is going to look really great, like new!

Brzn how are you posting pictures. Paint looks great!!

I'm using Imgur to post pictures.

Thanks and Happy New Year!!