Motorcycle Repair: ZX9R Muzzy cylinder kit, Im using too much oil !, washington state usa, piston ring

Question
ZX9R Muzzy cylinder kit, I'm using too much oil !

I have a 2002 Kawisaki ZX9r that I just HAD to install the Muzzy 998 overbore kit on. (new overbored cylinder block, new pistons, rings, headgasket) Now I'm thinking that was a bad move. Never-the-less, here is my problem:

I'm burning a quart of oil every 500 miles! I have no oil leaks otherwise. It is clean and tight. All the plugs look the same, dark tan. Why don't I see any oil on the plugs?

I'm a little worried that I installed the second set of rings upside down (the black iron ring, just below the top-most piston ring) I was VERY careful when I installed the oil rings. I am certain I did not damage them. This is not my first engine build.

Thanks a million!
-Robert
(Washington State, USA)  

Answer
Hi Robert,

With respect to your experience and knowledge, the first two rings are compression rings. I suspect the oil rings to be improperly installed (if any) causing oil to get by.

Consider this...Suzuki says up to a quart per 1,000 miles is considered normal usage on their litre bikes.

Your spark plugs being in good operating temp ranges indicates the oil usage may seem excessive, but not affecting combustion. Does the exhaust exhibit smoke? When? During cold starting, after warmed, always, or rarely?

I would do cylinder compression and cylinder leak-down tests, then contact Muzzy with me readings. They should offer tech assistance and be able to pin-point the problem quickly for you. They've heard all complaints with their kits.

Please advise on any intel you gain from your investigation so I may assist others in the future.

Respectfully,
Mark Shively
mcso429@netzero.com
Dayton, Ohio