Okay- so the day has finally come! I am going to start this beast up. Worked all day yesterday going through wiring issues and now I finally have spark!!! Thank goodness for the factory manual and an Ohm meter.....

So I just went and got 5gal of aviation fuel, a bottle of Maxima Castor 927, mixed 32:1  I have been reading all kinds of oil to use in transmission. What oil do you guys recommend? As far as break-in goes, what all should I do to properly accomplish this.  I don't want to start getting impatient now, this project has taken a long time and I really don't want to screw it up now.

Thanks in advance!

When you were able to get it to start, what was your procedure? When you rebuilt it did you clean the carb completely? Choke or no choke when starting?  When it did fire up, did you give it a lil gas and it died or did it just die at idle?

I tried rolling it over to prime it with  the choke on and then a good hard kick. It has the Mikuni on it. I sent it down to Jerry Hall for him to work over so it is now 41mm I believe.  He jetted it based on my altitude, and the Uni air filter.  He also did the cylinder work, set the squish and o-ringed the head. When I put it back together, I used the billet washers and RM250 wrist pin bearing.

When I say it fired, ignition was made, but not long enough to do anything. At first As I was kicking, I left the throttle closed. I then tried WOT and kicked it over. That really caused a major kickback, the back of my leg is black!!!

Based on my Ohm meter, my ignition coil is 1.79 on the secondary. The manual says it should be 3-5. Not sure if this would cause it or not. When I pull the plug and ground it to the pipe while attached to the coil I can see the blue spark.  From what I am reading, there is a technique to this. I am trying but just have not found it yet.

I guess I didn't because I have never heard of doing that. How do I go about it? I did not see it in the manual. Thanks

Okay- so the day has finally come! I am going to start this beast up. Worked all day yesterday going through wiring issues and now I finally have spark!!! Thank goodness for the factory manual and an Ohm meter.....

So I just went and got 5gal of aviation fuel, a bottle of Maxima Castor 927, mixed 32:1  I have been reading all kinds of oil to use in transmission. What oil do you guys recommend? As far as break-in goes, what all should I do to properly accomplish this.  I don't want to start getting impatient now, this project has taken a long time and I really don't want to screw it up now.

Thanks in advance!

Disconnect the fuel line from the carb and drain about a pint or more into a quart jar.  Shake up the fuel in the jar.  Is the fuel cloudy or crystal clear?  Clear indicates the fuel and oil are mixed at a molecular level.  Cloudy indicates the fuel and oil are not compatible at the current fuel temperature. 

Avgas and 927 has problems mixing at a molecular level when the fuel temperatures are below 60 to 70 deg. F.  This is also true with many high-octane race fuels.  Always check your fuel for cloudiness when the weather and fuel start getting cold.

Putting a quart to a half-gallon of premium pump gas in to 5 gallons of Avg gas will usually act as a good blending agent to keep the 927 mixed at a molecular level.  You cannot tune a two stroke when the fuel is cloudy.  The engine will not be getting the same air/fuel/oil mixture every engine revolution.  After cloudy fuel has set a short time the fuel will become clear because the oil has settled to the bottom of the float bowl and fuel tank.  At this point the engine will be trying to run on pure oil.

Anything that is below spec will not function properly. 

lots of ppl have complained about avgas and 927 separating at colder temps too.

Well ordered up a new ingnition coil today. Tried again using all of the advice above and no go. Got pissed so moved on to my 1974 bronco. Just  a few more wires and fuel injection/4r70w swap will be complete.
I will try on the zilla again tomorrow! Hopefully by then my calf won't still feel like a giant charlie horse!!! Thanks gus I appreciate all of your help.

Here is my '74. I just finished with the EFI and '98 Explorer 4r70w Transmission install.  This has been a 3 year frame-off resto.

Yippee! After waiting for my replacement coil, picking up a couple new plugs and finding a new stator from a guy here locally I finally got back after the bike. Today it started, very tough at first, but then away it went. I let it run to warm up and then it started to run away at the idle so I shut it off.

I waited until it was cool and got after it again.  It didn't want to fire up. I pullled the plug, still had spark, kicked the bike over several time with no plug, put the plug back in and vroom, started right back up. It really seemed to idle evenly, I know there are adjustments that need to be made, but it seemed pretty smooth. I would rev it slightly, let it come back down, rev it slightly....It did not run away this time.

Went to do it a third time after it cooled down completely and same thing. I must be getting some fuel build up, because it really explodes very loud in the pipe at first. almost like a huge back fire. Once I repeated pulling the plug (plug looked great not black, but more of a nice tan) kicked it over a few times without the plug in it, put the plug back in away it went again. This time it ran for bit then but then wanted to die. I can see there is fuel in the filter so it shouldn't be running out of gas. Maybe too much fuel? Kind of strange. 

I am wondering if the float level is too high as I am getting fuel out of the overflow. I am also seeing fuel around the manifold where the pipe connects.  I did what Jerry suggested and added some premium to my avgas/castor mix. It really seems to be more mixed now. It was in the upper 20's low 30's today so figured it can't hurt.  Any suggestions

Today was awesome. I took my first ride on the zilla. Finally got around to pulling it out of the garage and firing it up after winter! It was a **** to kick over at first but when it did, it roared to life. I shut it don, let it cool and did it again. This time I was able to get run at an idle. It purred.  Tonight I fired it up again and took it for a ride. No plastics or seat, I just sat on the frame and took off. I couldn't wait any longer! This has been 14 months in the making. Gonna take it down to sand lake here in a couple of weeks.

I still need to bleed the brakes, and hook some lights up. Almost there! New exhaust would be nice, but he fmf will have to do for now.

Congrats man! I'm not even to roller status on my build yet hopefully with some late nights this week of polish work I'll have a roller by next weekend. Then it'll be time to get my cylinder back on new piston installed and mount the motor and Q pipe! I can't wait to be fighting it to come to life for the first time!! Congrats again and enjoy!

It was sweet! Can't wait to get her to the dunes and see what it will do. Gonna be a whole lot different than the 4stroke kfx440 I have been riding. One question though, it bike seems to have a bit of vibration. Is this normal. Reminds me of the Harley's. hands are going to get numb. I really don't have anything else to compare it to. I will post some pic here in a bit. I still need to put the plastics nod seat back on, but you get the idea!

Also, I am thinking a bigger pilot jet would help with starting. It is a bear to start, if I hold the throttle wise open it starts on third or fourth kick. Would a bigger pilot help out with his?