I may not have explained how I would apply the jb weld but I would putt a little around the threads and send it in and ASAP once it’s in I would add some in the area where the chunk is missing and a small bead around the entire plug where it meets the engine to be safe. It has to be clean though and even if you want rough the area up with a little sand paper.

and remember to have the battery disconnected before welding or you'll be replacing the electrical on your bike too...

Ugh thats bad. Jb weld will work great though. Use the tap plug. Drain the oil lay the bike on the side so no oil is in the area of the threads when installing the plug back in. Clean it a little with a carb cleaner and dry It good so no oil is in the area. That’s why you have to lay it on the side and let it sit like that for a few min. The only other thing to do it bring it to a weld shop and have a guy that’s know heli arc alum welding and weld the tap plug in place.

View File 1987-1992 Suzuki LT250R Race Porting Instructions 1987-1992 Suzuki LT250R Race Porting Instructions Submitter Ajmboy Submitted 01/28/2019 Category Suzuki ATV

I would look to see if there is a compression relief lever on the head. Some of the bikes (not sure on your model) have this to make pull starting easier. I would also pull the spark plug and see if the engine spins any easier. If not there is something obviously holding the engine back. But try that first and see what happens. If it’s still tight we will go into it further. As far as the pull start having to be jiggled a little bit there is a spring that ejects a metal tab into the flywheel “cup”to spin the engine when you pull on the start cord. My guess is it has to be taken apart and a new spring and or tab needs replacing. Parts manual will show you exactly what the part names and locations/part number to get.