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Dan I've never seen the parts you are modifying but from the drawing you just posted, would'nt it be simpler to machine the shoulder of holding pin so you could slide the spring further in and compensate with a washer outside the indexer ?
I have followed your thread with a lot of interest since the beginning, I tip my hat to your patience and the fact you share your find.
Guy
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Where did you get that mount, and can you post a closeup picture, I've bought a 1 liter fuel bottle, but I have not yet figure where to install it.
Guy
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The footrest position on that 250 is exactly where I fitted mine. I like them there and the bike work well for me. The most important thing is it work well for me
Guy
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Any crank rebuilding shop should be able do the job quickly on a single cylinder motor but, if someone '' played '' around and bent the end of the crank trying to take the flywheel off, that's another story.
Guy
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I have never seen a TY TS piston like that.
Guy
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I looked for a long time for an oversize TY mono piston in Canada and the US, I found a 3rd os with ring that if i remember cost me $215.00 US I still have it on the shelve even if I sold the bike. I think it's a relic.
Guy
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How about the taper of the flywheel ?
Guy
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That's what I did with my levers, the reason I did it was to help me with control. It worked for me.
Guy
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Now that you feel confortable and relax on the bike, practice is fun, so improvement come easy.
Guy
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Hang on there, bread slowly look at the bike and make the adjustment that feel right for you and find a place to practice where you can ride until you are confortable. If the bike still scared you after say 4 or 5 hours of practice, than rethink your options.
Guy
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I don't think carb cleaner is that effective anymore, maybe an ultrasound cleaning would help.
Guy
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To add to David's post, the effect of the modified flywheel is not only felt in acceleration, you also feel a difference when you shut the throttle down. I tested my bike with a B model flywheel ( extra heavy ) and one with no ring back to back on the same sections, riding in the parking lot was not convincing, but when you get in a tight section, than you feel the difference. I have to say that I use the clutch more with the '' no weight '' flywheel.
Guy
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First I had to take it off my 03, I used a set of '' water pump '' plier to free it off
Guy
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I've also been riding my TY ( s ) without flywheel like Tony 27 for the last 10 years. I remember marking the first one I took off just in case I would not like the feeling, never bothered after that. Not all riders like the feeling, the Bultaco guys in particular.
Guy
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I replace the original head gasket with a thin aluminium one that I made from the original model, it does change the compression. I ran that for a while with no issue.
Guy
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I saw that on the NETA web site Sunday morning, I was looking forward to that event as I have relative in the area and we where planning to go, but after 20 years of putting up the event I understand the organiser.
Guy
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I had to shim the lower end of the shock on mine, ao I think you will also have to.
Guy
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On my bike, I welded the shock mount on the tube, I have no problem, but I'm not an expert rider so I don't ride as hard as one.
Guy
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Dan, do you plan to go at any of these events
Guy
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Also, why put gusset behind the upright ? I did not, and I never had any problem.
Guy
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Cascao, would you be willing to adopt an old man, I don't eat very much, I'm a quiet person, I'm pretty handy and I would wash your bike every week ! We did receive our foot of snow.
Guy
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Will you stop that Cascao !!! Weather Canada is predicting 40cm of snow tomorrow here in Québec *%?$***
Guy
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I they live like us in Canada, they are probably looking outside and swearing !
Guy
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I can't count how many time I was offered to try modern bike, but I always was reluctant, I don't know why. I've been riding for a long time TS and I'm certainly not a top rider. I mostly ride in the mountain. Don't ask why, but 3 years ago in winter, I suddenly had that crazy idea to buy a modern bike ( probably old age crises ), I found a well kept Rev 250 2003 at a good price and bought it. I just installed a slow throttle and off I went. It's very different from my TY or any other TS I rode, but when I calmed down after a couple off hour riding, I found it very pleasant and easy to ride. A 250 was and is a good choice for me ( I trade the Rev for a 2015 250 Sherco this fall) forgiving when I was not in the right gear and fairly easy to ride. I was well advise by a dealer before I made the move : don't be rushed to buy, a well bought bike is an easy bike to resell without loss if you don't like the experience. I vote go for it !
Guy
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