The answer to the rpm question is pretty easy. Take a look at the EVO dyno charts in the catalogue for the kit and HP rating for that kit, then look for the max rpm. For the BC 250 the HP pretty much doesn't change from about 7600rpm to the 8500 rev limit pre-set in the ECU. Most guys like to run around the 8000rpm mark.
For the primary there are a lot of guys running MDS weights. We've also used CPC, D&D, dalton and power quest. Everyone has their own very specific thoughts on what they like for engagement and finish rate on the primary spring. Personally I like a higher engagement than most. Steve at MDS sells most of his weight kits with a Polaris black spring.
We've tested a box full of secondaries clutches set up with different helixes on both the super and big chute kits. After changing out secondaries and testing on the snow all of us felt the 36/44 worked best on the 215-250hp kits. Set ups are dependent on how you ride, where you ride, and what you expect out of your sled. We've test every EVO kit on the snow with a lot of different set ups. So best to call with questions.
1-801-EVO-1590 for western US customers. For Canada get a hold of Gene (justboostit) at white knuckle motorsports he will be a wealth of knowledge.