As far as I can tell the front pulley is on proprely, its got a notch so it will only really go on one way really.
I started it up again this afternoon and it goes much easier now. I still have to have the choke on though but I guess this is normal with carb engines on coldish days. It doesn't sound as irregular now either on the exhaust strokes. I did an air leak test on the bike manifold using a blow torch with just the gas running (no flame) and moved it around the manifold to see if the engine would pick up. I've definitely got a decent leak at port one and a smallish one at port 3 i think.
I'm not surprised really as it looked slightly warped at one end after I welded it as I don't think I had it clamped down to the jig well enough. Is it considered acceptable to just go round the manifold and squirt a load of something like holymer blue to plug the leaks?
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