Noahdog, tell me everything you know about putting a kick start on an SR250 .. *grabs you by the collar* EVERYTHING! I really want one on my bike
By "porting" I mean I reshaped and enlarged the intake and exhaust ports on the cylinder head to increase the gas flow into the cylinder. Reducing restriction here means the engine can draw in more air/fuel mixture every cycle, increasing it's volumetric efficiency and thus producing more power. Smoothing the combustion chamber with a more uniform finish and polished finish reduces "hot spots" and deters pinging.
Anyway I've been really busy with the bike .. Since I got it running and checked everything was okay, it was time to put a final coat of paint on the engine and get it ready to put back in the frame for good! I am so sick of painting and taping .. I did manage to chip it once while putting it back in the frame but I can touch it up easily enough.
I also followed "Ken's Electrolysis Setup" and it turned out very well. Here's a pic of my setup using a car jump starter, some test leads, the rubber gasket from the bottom of my old fuel cap, a coat hanger and some washing soda! I love MacGuyver.
Here's the motor on the bench, painting and cleaned .. valve clearances and cam chain tension done, final torque'ing done, starter in and ready for the side cases.
And here it is back in the frame all plumbed up .. I am so happy with it! I used a spring to stop the fuel line kinking (it's a fairly severe turn from the petcock into the carb) .. there's a commercial product called the Unicoil for this purpose, which I bought and had to cut up and modify anyway. I think it looks really cool .. I kind of wish I had more hoses!
All fasteners on the motor (besides the crankcase bolts, I didn't want to disturb the seals as I wasn't planning on splitting the cases) have been replaced with high tensile cup head set screws with a black oxide finish. A lot of them are specific lengths and dimensions for this model, so I've had to modify their lengths and the shoulder bolt that goes in the bottom of the oil filter cover I had to turn down in a lathe as it's an odd size that was not available from the usual fasteners suppliers.
All of the original bolts for the motor mounts were assessed, cleaned with a wire wheel and then polished by hand.
Here's the frame, tank and motor all together at last .. also notice you can't see the wiring .. it's there, painstakingly hidden
I just realised that I'd already wired it up ..
Cheers