KZ 1000J cam chain guides

I have a 98 KZ1000 Police (J engine) I'm working on that has a noisy cam chain. When I measure the slack per the service manual, the chain is 1 mm from being at the service limit. The tensioner cross wedge position gives the appearance of the chain being worn out. The bike has 54k miles on it, but I think the top end has seen some service fairly recently. The intake valves are really clean looking, viewed from the ports and all 4 cylinders have 175 psi compression. The bike will only be ridden infrequently, used to play around on, bike shows etc.
The tensioner guides are pictured below. Never really seen any worn out ones that looked this smooth and uniform.

I'm trying to consider my options. Splitting the cases is not really one of them.
1. Install a manual CCT to get (maybe) a little more adjustment.
2. Replace cam chain with a new one with a master link. I have the link press tool.

Thanks
 

Installed a new split chain in my 82 KZ1100A motor on March 24, 2022.
It was removed after 15K miles when the engine was disassembled in late 2024. 
I still have the like new chain and a new master link, but doubt I will need to use it again...though I would not hesitate one minute to do so!


December 3, 2024

🙂

I decided to go with a new chain & master link. I'm having trouble with pressing the master link. I guess the press tool I have is not the best or I'm doing something wrong. When press the link together, it's too tight. 
Daveo looks like you has great success with yours, what should I be looking at ?

poptheclutch wrote:

I decided to go with a new chain & master link. I'm having trouble with pressing the master link. I guess the press tool I have is not the best or I'm doing something wrong. When press the link together, it's too tight. 
Daveo looks like you has great success with yours, what should I be looking at ?
 

Spacers are needed behind the outer link pieces.

I utilized feeler gauges to measure the gap, and used two that fit tightly after cutting them off from the pack.



Procedure video, while available:
photos.app.goo.gl/cAyyLYXD5zmwQ7w38

🙂

Sweet ! That's what I needed. Glad I bought extra master links. Been working on bikes a long time, but this is my first time dealing with a multi-plate chain. Thanks

poptheclutch wrote:

Sweet ! That's what I needed. Glad I bought extra master links. Been working on bikes a long time, but this is my first time dealing with a multi-plate chain. Thanks

First time here too...

Saved a tremendous amount of work, money, and...time!

🙂