break in was up and down with the throttle, never holding a constant rev.. i though maybe the fan was the problem, after it was good and warm, it didnt want to start, but cold,, it starts first pull every time. what i was saying about the fan,, it dont turn without force, like its almost completely froze. i just dont know what to do with the hard start when hot,

 

Like I mentioned with a new bore you should have more compression than 125psi you mentioned. If it runs good cold,crappy when engine is warm or hard to start when warm,then I believe the problem is still piston/cylinder related.When cold the compression is enough to start,as it warms the cylinder expands and rings start to loose their seal against the cylinder walls. When it does this do another compression check.If it's lower than what it was when cold,then you need to go back through the top end. Isn't the first time I've seen this happen to people that had them bored out at machine shops,etc that allowed too much clearance in most cases. Plus the fan shouldn't have anything to do with what's happening to the engine and hard starting problems.

 

I took it out for a ride,, got it good and hot,, as weird as it sounds compression went up... 132.. but i did find something.. my gas line was going up hill then down, that and almost out of gas.. gee why did it die... lol.. i remade the gas line so it was all down hill, did not put more gas in, took it for another ride, low and behold,, its a rocket,, well as much as a 250 can be,, 1 pull cold, 1 pull hot. i would say this is fixed and ready to rock, but i still hate the sound of a 2 stroke... lol,,, btw my ride was about 45 min, to make sure it was HOT.

Hard start problem solved.. Thank you very much

 

Glad it was something simple and not what I feared.. Compression can go up as the rings break in and mate to the cylinder walls. Now all you need to do is ride it and wear earplugs if you hate the sound of 2 strokes..