Originally Posted by RideFreak
THe brush length difference is because the outer brush has more material passing it due to it's loc on the diameter of the stator. THe toasted stator probably didn't help ether. I'd replace the small phillips on the points etc with some allen bolts.
RD250s with a 350 jugs make a pretty hot little bike due to the difference in primary gear ratios from the 350. Match porting the pistons helps it run a bit better with no adverse affects too.
Ah yes, longer path of travel, makes sense. And thanks for the other tips. Right now my plan is to get it reliable and see if my son is into the bike. If he is, I'll see if he's into doing a proper restoration.
Other than that I'm sort of on hold for a few weeks while I sort out some house projects. But I will be back to it soon. I also may have gotten a bit ditracted by a new toy I picked up for myself (a KTM 690 Enduro), but that's another thread...