046,
Changing the cyl base gasket from the .031 thk paper to the manilla paper makes a small, but i think noticible change in compression. Plus, thats a good mod to make if you are changing cylinder/piston anyway.
I have heard of people polishing both mating surfaces, and using a "dead" fit, but the manilla paper is only .005 thk, so its easier for me to run with that.
Merc Marine and Bombadier use it all the times, so its okay stuff.
Your totally right on the exhaust port and gasket, they can be pretty far off, so alittle time with a die grinder there is well spent, plus smoothing it out helps it flow a little better too.
Now, the intake. Depends on the saw,, but most can benifet tons just by checking all the intake ports and cleaning them all out. I have seen many with alot of molding flash, and sharp edges left in them. Just smoothing all those out will make 'er breath a lot better.
If you do these mods above, and open up that muffler, you will really bring that 024 to life! I have a 024 too, and it needs exactly the same thing. A dealer had it, with a bad piston, and slightly scratched cylinder. they tried to hone it,(bad plan) and it held for a while, but its getting replaced with a new piston and cyl before next season.
As far as changing port timing, thats pretty much for competition, and i dont go there...not much of that here in IN. I have some ideas there, but i havent unleashed them yet. But maybe, by the summers end, I may have taken the die grinder and either successfully modded the port timing, or trashed a cylinder and piston!
And now for the disclaimer, I gotta add it!
DISCLAIMER:
My 13,500 in the cut is a freakin blast but....I have only ran it for one season, 50 or so tanks of gas, so its still unproven and could result in a trashed saw!