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my approach would be a small hole drilled thru (yellow circle) and safety wire (green line) the pivot pin down into the old part left. 0.02

I've used a similar repair method on a Mikuni carb and it works well.  Use a drill press to ensure you get a straight hole drilled in the carb body.

No....not for me.  Can't help but wonder what the possibility is of tweaking that long skinny frame member should there be a get off...especially at the top mounting point. That's just me...

That's a great looking RD250!...and with the front drum brake too!
Looks very good indeed.  Hoping my long time 73 RD250 project turns out as nice as yours!
Well done...

I've been reading up on the DS7/R5/RD250/RD350 clutch differences.  The write up by SUPERTUNE is fantastic - thank you for all the work and effort on this.

I have a 73 RD250 project that is turning out to be a mix and match affair when it comes to the clutch assembly.  I seem to have the correct later style clutch hub, metal plates, fiber plates, thrust washers, to be able to install the later 7 fiber plate clutch but I do not have a later pressure plate....I have the early clutch plate available only.

Would the clutch work with the old style pressure plate on the newer style clutch hub with the 7 plate set up?

Is that pitting on top of cylinders or is that head gasket remnants? 
Coolant level remained constant? 
Motor wouldn't have been sucking in coolant maybe?  Specifically on the suspect cylinder.

I don't know much about Suzuki 2 strokes so just thinking out loud here....