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But the chain already rides on the metal cogs of the cams and seems to survive all right (all tensioner issues aside) and the nylon cog is a know problem - or is the problem one of sourcing an OEM replacement rather than it being an inferior part?

What I said might apply more to the water pump gears. In case of the tensioner, looking again at the wear from the chain, it crossed my mind that plastic is used just for this very reason - to accommodate wear and prolong proper function. Instead of the chain deteriorating and needing replacement, it's easier and cheaper to replace the sprocket than the chain. Any wear which shows on the nylon sprocket would otherwise affect chain if a steel gear was used, or further affect and wear the gear on the cam shafts. So, perhaps this non-metallic sprocket was used specifically to absorb wear in order to prolong life of the the whole set up, make accurate tension adjustment possible over a longer period time, and to protect other more expensive parts as mostly cam shafts, and the chain itself.

Don't disagree with your rational stang. It's just ironic and disappointing that to replace the cam-chain tensioner Nylon sprocket, you have to remove the entire top-end. That in itself seems counter productive and adds a major expense. It seems absolutely stupid to have to replace a perfectly good head-gasket to replace a simple part. I guess KAWI. didn't think these bikes would last that long or maybe THAT was their plan, all along.

Agree Scotch! That wouldn't be the first nor last backward thing those companies do. I think it's a mix of cutting the costs, building based on what they already have instead of redoing for better and functional. Pus - wouldn't be surprised if it's a big one - making things difficult on purpose for a home mechanic and investing in future cashing on brand name service and replacement parts. You require special tools, awkward procedures and designated shop spaces. Your engine turning by hand improvement for example. It just puzzles me why the bright designers at Kawasaki wouldn't implement it especially that it comes as standard feature on other bikes of the same age!

Also a good point about not lasting long. On the other hand it did! 1979 until last year produced, and modified in the meantime in such a big way as switching from carburetors to injection? But the nylon gear stayed, right? There must be an alternative reason beyond just trying a new bike line in my opinion. Perhaps that's what they just saw as the best middle way solution at the time, without any deep sinister evil planning. I guess that's why Bentley's cost so much...

Another mock up of the handlebar. I've had no success following on a promised one, among other crucial to my restoration parts, made with one of the forum members, but I am not out. Got this handlebar, took apart completely rotten master cylinders and controls. The master cylinders need re-sleeving. I am in the process of a DIY rescue. So far stripping, cleaning, and sourcing parts.

All the electrical/mechanical controls have been disassembled and rebuilt. Except the top painting, which I am not in a hurry to do. This and lettering will come as ice on the cake once I am sure all works properly.

The mirrors are from eBay. Love the square shape and field of view when I sit in my chair and watch my back! HAHA They were listed as similar year police model. The plastic needs some attention (please any plastic refurbishing tips come in!), but the perfect mirrors were what sold me on these.

So here we go with yet another mock up:



I also finally removed the stuck broken lid screw of the rear m/c. All is ready for re-sleeving and then painting. Then - assembly!