1. >>1992 xr250r shock (free) that I was just wondering if I had a custom spring put on it, would the valving take the heavy spring and weight of the heavily loaded bike
<< I'm pretty sure you'll find that the XR250R damping is hopelessly inadequate for the job, especially if you add a much stiffer spring to it. The shock is carefully designed to provide adequate damping on compression and rebound with a particular weight and spring - you're going way outside the acceptable parameters. I think you'll end up with a pogo stick!
2. Have you tried Progressive, Works, Pettersson Pro Suspension (at http://www.ppsracing.com/)
or White Power? Failing there, take your old springs to a wreckers and start comparing springs - you may end up with something very close - there can't be an infinite variety of springs, there are only so many dimensions to play with here! Progressive may even be able to match you up with something close - assuming they have a database of spring specs.
3. Fully enclosed chain is terrific, I've had experience with them on old Bultacos, BUT trying to build your own is a big job and not one I'd care to tackle. Modern chains are much more durable. Try a ScottOiler - they seem to work a treat, everybody I know of that's tried one loves it. Having built them myself in years past I'd say yours is too messy because you're using too much lube, or too light.
4. A heavier chain is just that, heavier, but not necessarily stronger. A 520 is however not a particularly big chain for a 600. I used to use a 520 on a 175!
Shouldn't be too hard to go to a 530 o-ring chain. Check your dealer.
A BMW is A solution ;-)
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[This message has been edited by Grant Johnson (edited 23 June 2000).]
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