Suzuki DT200 Rebuild/Replace 1 or All Pistons?

miwise

Recruit
Joined
Dec 30, 2005
Messages
3
Hello,<br />I have a 1986 DT200 Suzuki, and one of the pistons has a hole in it. The other pistons and cylinders look good, but the compression in the other 5 cylinders range from 70lbs to 105lbs. <br />Which scenario should I choose? Is one better than the other? Will Scenario 1 work for a while until I can purchase a new engine? Thanks! <br /><br />Here's the scenarios:<br />Scenario 1: (hopefully all cylinders equal displacement)<br />1. Have the bad cylinder bored and sleeved <br />2. Replace bad piston w/oem piston<br />3. Hone the remaining cylinders (as they are not scored and pistons still good) <br />4. replace rings in all pistons<br /><br />Scenario 2: (all pistons equal displacement)<br />1. discard all pistons<br />2. bore and hone all cylinders (no sleeves)<br />3. install brand new oversized pistons in all 6 cylinders<br /><br />Scenario 3: (one piston w/more displacement)<br />1. discard only the bad piston<br />2. bore the scored cylinder<br />3. hone all cylinders<br />4. install new rings on old pistons<br />5. install oversized piston and rings in newly bored cylinder.<br /><br />I would like to do either scenario 1 or 3, but I was told that scenario 2 was the best method. wanted to verify with 2nd or third opinion. I have seen recommendations online in the direction of 1 and 3.<br /><br />Also, does anyone have any recommendations on a good machine shop that's reasonably priced to whom I can send the block to have the work done.<br /><br />Thanks for any help!!!
 

rodbolt

Supreme Mariner
Joined
Sep 1, 2003
Messages
20,066
Re: Suzuki DT200 Rebuild/Replace 1 or All Pistons?

the cyls on your 200 are detachable. my advice would be to contact someplace like Fridays marine in saluda VA and discuss sending your pistons and cylinders to them for inspection. the pistons can be replaced without opening up the block if you wish. but at a minimum the cylinders aned pistons must be properly measured after any cleaning and honing is done to insure its all within the service specification. <br /> you can make the special plate needed to assmble the banks back to the block. I have done it once in a buddies garage without the plate and used a staightedge and a feeler guage.
 

miwise

Recruit
Joined
Dec 30, 2005
Messages
3
Re: Suzuki DT200 Rebuild/Replace 1 or All Pistons?

Thanks for the advice! I will have the cylinders and pistons measured to determine if they are w/in tolerances. Does anyone know what those tolerance specifications are by any chance? Thanks!!
 

rodbolt

Supreme Mariner
Joined
Sep 1, 2003
Messages
20,066
Re: Suzuki DT200 Rebuild/Replace 1 or All Pistons?

they are in your service manual. you do have one right?
 
Top