Thanks for taking us along on this adventure, Tom. So many things can contribute to oil consumption, and a combination of a couple of them would be impossible to pin point I would think. Valve seals are bigger culprits on today's engines more often than rings. I have no evidence that this is an issue with the KLR. Break in procedures, operating temperatures, load weight, wind, operator riding habits, on and on and on...... Ring flutter would be hard to confirm outside of a laboratory atmosphere, and even then to be able to replicate the oil usage amount with consistency would be difficult.....
And if the cylinder is the issue [distortion being a top speculation concerning oil consumption], how is the cylinder improved by reaming it out, creating an even thinner cylinder wall.....although it seems to work.
"Head work" is a black art in my book. Larger valves serve a purpose. As far as the porting, how much is taken off where is a mystery to me. I can't pin anyone down to specifics as to where they machine, and how they determine how much to machine off. Polishing makes sense to me. I have no proof it enhances performance, but it makes sense that smooth surfaces would enhance flow. Hopefully I will learn as I follow along here. I have every confidence that this project will be done right, and all outcomes will be reported objectively. My bike, the "'Little Valdez", is pushing out about one and a half gallons of oil per 1200 miles. I need a solution and will be watching carefully.
many a trip continues long after movement in time and space have ceased- Steinbeck, [I]"Travels with Charlie"
[FONT="Century Gothic"][I]Sometimes your only available transportation is a leap of faith[/I] [/FONT]