Have you checked that the clutch arm has the clearance it needs? I seem to remember guys having difficulty with fitting a non crank mounted clutch engine in these.. it will be a nice little bike when your done mate
I'm going to need quite a few bits, the plan is to have it ready for next season, so I've got some time. The GPX forks are too long and even if I cut the springs and shim them they are still going to be too long. On the lookout for some 600mm or shorter forks now, I may even get some KTM 65sx legs and shorten them!!!
Stuck the stock KTM 65sx brakes on with the 220mm disc because the bleed nipple is so close to the rim with the 240mm, just to check the fit! Will need to make up a relocating bracket, but considering I won't need the same sort of stopping power in the wet, these might be the go!!
How much room is there between the disc and the stanchion?
Could you space the disc off the hub with some 3mm or 4mm thick machine washer's to give the bleed nipple more clearance ?