snip The older early 440 srx's, exciters,vmax 540 engines were the worst. You can weld up the spots and rebore it and new ones(porosity spots) appear, its the quality of the yamaha casting, not milleniums fault.
snip
Seems to me if I sent one of the above to have plated and wasn't told of the possibility of porosity during boring - and received a cylinder that was plated over the porosity it'd darn sure be they're fault. Perhaps a disclaimer over the phone before the customer sends it in.
Something like - "Our experience suggests during the boring process we may uncover porocity that isn't easily repaired. If we find any we will call you with options". In other words, lay it out before hand what issues may arise.
Of course before they know which cylinders are prone to such issues they wouldn't be able to tell the customer before receiving the cylinder but it still wouldn't excuse replating a porous cylinder.
Sounds like something my first Polaris dealer would have done... if he was still in business.
IMO.