Larger power valve cover for a 250

I picked one up to try, hopefully there's enough clearance when I add the estart

Sorry, but no. There is not enough space for a spacer. The max you can put between is 2mm but that's not worth it!

I made a CAD model for a spacer version but it is much too expensive for me as a privateer to pay for. Making 5 pieces would cost more than 150,- euros per piece. The problem is the high milling volume which means time on the machine.
 
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I decided not to make one of these spacers and go the Elvis route instead. Hopefully I'll be able to ride some with it before the end of the season here.
 
Only 10 and 15 mm

Some friends tried 2x 10 but the result was similar to the 15 mm. But the 15mm fits better and looks better.
You will be happy for sure :)
 
Sorry, but no. There is not enough space for a spacer. The max you can put between is 2mm but that's not worth it!

I made a CAD model for a spacer version but it is much too expensive for me as a privateer to pay for. Making 5 pieces would cost more than 150,- euros per piece. The problem is the high milling volume which means time on the machine.

You tried laser cut?
 
The Standard spacer are water cut! Laser cut is very difficult because of cutting aluminum. Most companies I've ask only cut up to 8 or 10mm. The version for the e-start is a very complicated 3d geometry.
 
I guess the problem with the estart version is that it is not a spacer as you will need to get the volume by molding around the starter motor.

Back on the original topic, I believe the spacer has a better effect on the 250 than the 300
 
Back in 2002, my tool and die making neighbor made me a similar spacer out of 3/8'' aluminum plate (9.525mm) using an EDM machine (wire-cutting). Turned out great. Only difference from Elvis' piece is that it used a separate bushing for the center bolt, and I just silicon-ed that to the stock cover.

Seemed to add some low end to my 2002 300XC, and was pretty trick at the time. I later had a chance to get a real deal on a Checkpoint PV cover and am using that now. I think I may still have the spacer in my spares box if anyone is interested.
 
It's a 3D PDF where you can see how the e-start cover would look like.

Excellent work (pdf drawing rotates). I've thought about making one myself. I'm not sure of the depth available behind the starter motor, but you might need to add a counterbore so the center screw is recessed to clear the motor. Are you allowing enough space for the plastic cover/motor shield to be retained?
 
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