[a4twenty]

did you do a compression and leak down test prior to tearing it down?

 

[a4twenty]

Saw that. Would I need to take in the piston, and the boring instructions as supplied with the 685 kit?

would definitely help for them to have the tolerance specs. if it's OK, you just want a light hone to give the new rings a fresh start.

 

[a4twenty]

it is recommended to use a little RTV around the half circle, specifically the tighter rads but some don't.

you're probably going to want to get back in there to check the valves after they've seated, so it's up to you how you fix it but after all that money and work, I know which I would choose.

 

[a4twenty]

$88 here for a new gasket. Rip off!

never used one but google TUSK KLR valve cover gasket. they're about 1/3 the price of OEM here in canukistan.