Its easier to uninstall the cap when the forks are still mounted. Make sure to loosen the pinchbolts in the upper tripleclamb first.

And yes, the 102 sounds like 102mm from the top of the compressed fork (without spring installed) to the oil.

A frriend had to replace the right crank seal, he did it from the outside.

As fot cleaning the choke, as I said theres a passageway in the floatbowl, thats often overlooked when cleaning carbs, as people focuse on the main body. Im not talking about the choke plunger and where it mounts in the carb.

Just another thing to exclude

Yeah, most use 2% as a rule of thumb

I saw a chart on the auto-pump back in the days, as I recall it pumped out 3-4% af WOT, and way less just idling or at low throttle operations. Kinda shows you the beaty of the auto-pump.

Some info here: http://www.dansmc.com/2_stroke_oilpump.htm

Also, have a look at the reedvalves for broken or torn reeds.

Did you clean the choke passageway in the bowl?

Never had problem with non-original cables. I give them some light oil, and make sure to route them with a minimum amount of kinks. Often you can reroute them differently to get them even smooter.

But go eom if you feel like it

@DTR-NSR said in Hmm now what (A Rebore!):

Hard to tell in the pic but looks like the gudgeon pin circlip is missing? Unless you took it out before pic.

Yeah, and scratches on the side and dome of the piston right about at that point.
Good eyes.

Can HIGHLY recommend theese. You need an adaptorring for the stock headlight
The light will flicker a bit at low idling.
https://www.ebay.com/itm/Nighteye-H4-9003-HB2-8000LM-Car-LED-Headlight-Kit-Hi-Lo-Beam-Bulbs-6500K-White/391600374998?epid=907124270&hash=item5b2d3384d6%3Ag%3AqOYAAOSwlCdbGfEK&_sacat=0&_nkw=Nighteye+H4+9003+HB2+8000LM+Car+LED+Headlight+Kit+Hi%2FLo+Beam+Bulbs+6500K+White&LH_BIN=1&_from=R40&rt=nc

Adaptor:

https://www.ebay.com/itm/P45T-P43T-R2-H5-TO-H4-HEADLIGHT-BULB-ADAPTER-VINTAGE-CLASSIC-CAR-MOTOCYCLE/122807481195?hash=item1c97e5736b%3Ag%3AJ8gAAOSwh1haIcQF&_sop=15&_sacat=0&_nkw=H4+P45t+Headlight+ADAPTER&LH_BIN=1&_from=R40&rt=nc&LH_TitleDesc=0|0

Yes a 428 is lighter per link, but you also need more liks than a 520 because a 428 is smaller.
We've talked about the supersmall weight difference in another thread, so please, lets not go there again