Looks like the sleeve is off center/rotated. That cylinder is trash and if they ground on the power valve those too. Look for a non-sleeved used cylinder or new OEM.

https://www.scooterswapshop.com The owner also has a full service scooter shop. Im sure he can answer all your questions.

Not possible. Using the 04 cases you can convert to a 03 top end but you will need a lot of supporting pieces. I would stick with the 04 cylinder setup.

The discoloration is not rust. And don't use scotchbrite on a fork tube

Doesn't look like its missing much compared to the photo I posted before. Triple clamps, bars, graphics.. It appears that Gio's bike was mostly stock

The clutch plates brake down and will put glitter in the oil. You need to be changing it a lot more frequently. Like every two or three rides. If your not having any shifting issues or clutch issues, run it. Coolant would make it more milky so your good ... more »

The wrong transmission oil can cause this so can worn clutch basket or hub. Your clutch lever might also be adjusted wrong.

Joes ATV performance and fabrication. He is a transmission specialist and does custom transmissions. Look him up on facebook. You want improved shifting you get the transmission ISF polished and cut. If you are looking for durability CRYO treating is ... more »

If the cases, cylinder head, etc. Are all 100% prepped ready to go everything clean and checked all you need to do is assemble it probably 3 hours or less. Prepping everything and checking it all before assembly is what takes time.

These carburetors are notorious for problems. Look up KX65 carb swap. I have done the carb swap and airbox mods and it really wakes the bike up and it runs much better. I had troubles with my stock carb as well. If your on a budget though try adjusting ... more »

Im not sure what you mean by different race number. Gio's number was 716. I also found a signed Gio jersey with that number on google images. But as far as different plastics the team probably stripped the bike and pieced it back together with a lot ... more »

This is Gio Tedesco's race bike in 2001. It appears he used a 2001 cylinder while other team riders were using the older cylinder (look in background)

Looking at the Vault on racer X it shows Gio Tedesco raced four supercross races in 2001 on A Honda Cr125 so that's probably his race bike judging by the AMA sticker and welded skid plate tabs. https://vault.racerxonline.com/rider/gio-a-tedesco/races ... more »

If adjusted correctly It will not make the chain wear any faster. The Honda uses a spring loaded tensioner so I can see your concern. Other 250f's like the Kawasaki use a click type tensioner it cannot retract like your Honda tensioner unless removed. ... more »