my buddy has a zrt 800 and he lost a piston last year just one the other 2 were fine, well we tore the motor apart bought a new oem piston to match the others and got each piston a fresh set of rings, well before we put the jugs back on we took a hone and gave each cylinder a quick little hone, not much just so that the rings would seat well, i know your not suppose to hone nickelsil but do you thing what we did would be fine, the sled starts up and seems to run fine and the compression is all the same on all 3 cylinders, what do you guys think thanks for any info.

Yah, they say not too, but we have with every engine we have put back togather. You have to get some fresh lines in there. The key is to make just a couple passes, not too much!!

Who says not to?
I honed mine. And all told me to.

Some service books say not too. Right in the Cat Master book I have shows a bead hone going to town! I feel you have to give them a fast pass through.

Ah Hah!
I agree.

I have read nothing but how NOT TO,,, but it can be done as mentioned above. I have never done it myself,,,,,

thanks fella's i was just wondering this makes me feel a little better.

The only problem I've seen is someone using too much speed with a ball hone and chipping the nicasil around the ports.

You always need to resurface the cylinder for new rings to seat properly. Cat reccomends using a ball hone, and a skilled operator, using proper lubrication with the hone should give fresh crosshatch in in a few passes. My dealer does mine when I pick the new piston kits.

Had my ZR800 cyls lightly honed at the dealer with a ball hone..............perfect cross hatch / perfect ring seal after break in.

I have also ball honed all of my cylinders. No problems here ever.