It runs!!!! BUT!

Take a flash light and look in that cylinder while turning the crank with a wrench. You'll see the exhaust valve. Tell us what you see. If you're lucky and a lot of times it's only a maladjusted valve. Was the head done?
Steve

No head was just removed then put back on. New gaskets and o rings only. I have a valve shim removal tool on the way. I will check it out. I'm pretty sure I'm gonna need some shims.

Pull them out and buy some .004 thinner. On the offending cylinder go .006. I'd pick up a few in between just to have on hand. I'm buying some one stage down for my bike. Tell us what sizes you have.
Steve

When I get the tool and can remove and catalog what I have I will post it.

The shim sizes tell a lot about the motor.
Steve

The engine has 27k on it. Reason I opened it up was oil leaks. Just a plain freshening up.

The valves should be checked every 4000 miles or less depending.
Steve

Did you replace the valve seals? They should be done while your in there.
Steve

No I didn't. I didn't want to disassemble the springs and valves.

Well got shims and got all within clearance except #2 exhaust. It must have been out for a while and getting worse. Back to the Kaw shop for some smaller shims. Here are the readings before and after

Well got the #2 exhaust to .110 so I think all my clearances are good. I checked compression and it is at 90psi. To damn low. I put a little oil in the plug hole and got 130. I won't have a chance to try to start it till tonight. Think compression will build with it getting hot once it's running?

bromz wrote: . Think compression will build with it getting hot once it's running?

Yes maybe, sticky rings can free up just running it, but don't be too hopeful. My pressures nearly doubled from cold to hot on a motor that had been outside and not run for several years, on a couple of pots going from about 50 to 100 . I had intended to bore it out anyway, so I only run it up just out of interest and wanted to hear how it sounded. This sounds like nonsense I know, I was really quite suprised myself and hadn't expected it.