My first quad build Trx250r

Built a bracket for my keyed ignition and trail tech temp gauge/fan programer and started to clean up some wiring.

I got the motor test fitted and exhaust to measure springs. Also had to modify my DRW case saver to work with my TMR swing arm chain guide. Also got the decals on body and swing arm. A lot of little things to do still.

anyone have any suggestions on this? Plastic bulges out not allowing kicker to sit flush. Only thing I can think of is just cut out the plastic for it

On another note it looks like I fixed my other motor. Was leaking here causing a leak down test to fail immediately and leak air out as fast as I could put it in right through the trans.
Old crappy repair somebody did cases pretty much would not seal in this area they took to much off the surface near weld causing a .020 gap


so I had a local welder build it back up then I took a small die grinder to get most of the weld down then carefully used a file to get it closer. I stoped by a granite store and they gave me a big scrap slab so I used that and 400 grit paper to resurface both sides of the cases, where the cylinder bolts, the cylinder surface and the head. I’m glad I did because nothing was flat.

Just got my .015 base gasket on and made the inner part of the 3 pice head gasket .020 bigger with my dremel to accommodate my 67.50 mm bore. Just did a leak down and have zero leaks. Final UCCR is about 13.7

Well I installed the DRW ignition and floated the ground. The wiring off the stator needed some finagling to make everything fit correct. I used one of the pick up bolts to install an electrical eyelet so I can bend it over to secure the wires better. I must of done something right because I now have spark.

Working on restoring/repacking silencer started at 600 grit sandpaper and worked my way to 2,000 grit then polished.

Got my entire exhaust on spent over 3 hrs trying to get the head pipe to fit right/straight along with exhaust and muffler. Had to heat the exahust in places and bend it to get it to clear frame at the A arms, coolent hose to head and rear of the frame by the brake reservoir then chop off a 1/2 of tube to get the muffler on correct and bolted.
I also got my 38mm A/S short body carb, new intake to fit carb and a throttle cable. I got the throttle cable hooked up and the throttle is super stiff. Doesn’t appear to be an issue with carb or thumb throttle feels more like when there’s even slight tension on the cable it doesent glide freely inside causing it to feel stiff. cabble is a motion pro if anyone had issues with this cable please let me know.
tomorrow I’m going to attempt to start it after I do the 89 clutch mod and a few other things.