With the paintwork away, been slowly ticking off the long list of jobs before I can try to start the engine for the first time. Drilled and mounted the blank rear sprocket, had to be blank as the rear hub was drilled to match no other wheel in the known universe.. With that done could check on the chain alignment, with the ZZR1100 front sprocket, which in turn has a 5/8ths built in offset. Turns out that's not enough and its still 10mm out of alignment. Been trying to source a 1 inch offset front sprocket, but no look just yet. Another option is to remove and dismantle the rear wheel and machine down the LH hub by 10 mm.. luckily there is plenty of room between the chain run and rim/tyre.
The next job proved to be very frustrating, trying to fit the one off outrigger bearing support.. the inner plate wouldn't fit over the gearchange shaft, as the side stand spring tang got in the way. Something that should've been spotted long ago. But with the various C19 lockdowns it wasn't possible, as the engine and frame were in different workshops.
The answer was to fit the shaft through the plate, then fit its mechanism to the engine.. while the plate was in the way.. took a lot of attempts before I felt confident enough to fit the handmade gasket and fit it for real. Got there in the end. Though its support spacers for the outer plate need a little machining to get them to fit just right.
I painted the alloy foot peg hangers satin black, just to see how they look, they'll need to be hard anodised later, as even the so called 'tough' paint will soon be scratched otherwise.
Also fitted the duel cable throttle with a cable kit from Venhill, and measured and ordered the brake and clutch lines from HEL.