Join Date: Jun 2012
Location: MI/NC/AK/currently MO
My wife is on her second Rappy 250, first one was stolen, but at least it allowed me to experiment more with the second one.
First, if you care about saving money just do a slip on, factory header is not bad and in my opinion better than some of the aftermarket ones. There is a DG slip on on eBay for $150.
Intake- cut the screen out below the filter, make sure to clean up the edges good. Replace the stock filter with a twin air if you want to change that.
THE BEST MONEY SPENT- 10.5:1 piston and camshaft. I used the Vito's kit, it is $220 with gaskets, if you have never done this before, don't be scared, set up a date and have her help you. I did a lot of research, found some people having issues with the Hotcams in these 250's. But the Wiseco, Web and Vito's cams are good. You could probably do 11:1 compression but 10.5:1 ensures reliability, and I must say the wife and I are impressed. The exhaust note has even changed.
We did pick up a Procom CDI, not sure how much it helped with but I don't hit the rev limiter anymore :) my wife prob never does anyways.
We also got a wider axle and front suspension, parking brake delete and front grab bar. And are deciding on tires (the stock rears are garbage).
Also, I ended up sticking with the stock carburetor needle on the second one and she runs great, don't waste money on the GYTR jet kit it probably will not have the jets you need anyway.
Get rid of the fuel heater on the carb, it makes for faster removal, frees up about 10 watts and does not affect starting at all.
Hope this helps, and if you have any more questions just let me know.