It sparks, it floods, it has started 3 times, each time with starting fluid, runs for almost a minute having to feed it some throttle the whole time to keep it running, then it just dies and won't restart.
So it started 3 times across 2 weeks and 1000 kicks.

 

It is possible you bent a valve Or two when you were trying to start it with the timing out of whack.

 

I tend to agree that it is definately possible to have bent a valve. That is my next area to check out, I'm thinking that may not be the case since my valve clearance was so tight, if I bent a valve I should have loose clearance.

 

Good point. Will be interested to hear what you find.

 

rings or headgasket ?

 

Soooo it turns out my head gasket was basically blown. It was so bad that the cylinder was filling with coolant. Might have had something to do with me putting the motor together, taking it back down and re building it trying to cover all my bases and re-using the head gasket. Anyways i got a hold of Bill Blue and he sent me a replacement for free.

Heres what the head gasket looked like:






So i threw the new gasket in and the bike fired up in 3 kicks. It feels really strong and pulls hard now! WOO!

Finished up mounting the Vapor, made a bracket that mounts to my bracket i made for the head light. I think it came out pretty good. I mounted the speedo pick up to the fork guard and had to epoxy the magnet onto the brake rotor after having a clearance issue with the supplied rotor bolt and the fork. Also since my bike only had a tiny RC Car battery on it to power the lights i wired the vapor into the ignition but i am thinking of wiring the Vapor into the headlight power instead. It will be more efficient for battery life.
After trying 2 different stock length brake lines with poor results, i ended up making my own with a Russell brake line kit. Also got the tail light, headlight and turn signals wired in.



Also finally found a graphics company that has KLX300 templates. Powersport Graphix out of SC was the ticket, they were pretty great in dealing with. Sent me proofs and made revisions based on what i wanted and i must say i am extremely happy with them.

So here she is. A few tweeks with the jetting and a few more things to finish up.




Heres a list of all the parts and modifications i have done over this project:

Powder coat frame, swing arm, engine mounts and skid plate Satin Black.
New bearings in steering head, swing arm, and suspension knuckle.
1994 KX 125 forks
Rebuilt suspension with proper springs for my weight.
Anodized Fork tubes black.
Custom machined spacers for ride height and axle.
Powder coated shock spring Green
B&B 351cc Cylinder kit.
Mikuni TM-36-68 Carb
MotionPro Vortex throttle
MotionPro Throttle Cable (Custom specs, 4" longer, connector to mate with Vortex throttle)
Custom SS brake line (Russell components)
EBC Dirt Racers clutch kit with springs.
Green radiator hoses.
Renthal sprockets (15t/48t)
DID o-ring chain
Renthal Fatbar (CR High)
Renthal Grips (Med)
2009 KLX250sf headlight (Custom fitted)
2009 KLX250s headlight shrouds (Green and white)
CRG barend mirror
TrailTech Vapor
Moose Skidplate
Wide pegs
Moose shift lever
eBay Taillight from china.
2010 Ninja 250R master cylinder.
eBay levers for 250R from china. (awesome quality)
2010 KLX250sf rear brake caliper (black)


Will add more as i think of it. And ill get some DSLR pics up sometime soon.

 

Glad to hear you got it sorted out and enjoying the big bore. the 331 kit i put in mine really woke the bike up.

 

Holy crap batman, look at that list of parts. Nice job btw

 

Bike looks great. What was the total cost of the upgrade, if you dont mind I ask?

 

Thanks for the kind words guys.

Websurfing i think i have about $1600 into the project not including the bike.