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Thank you Scirocco, have you heard much about these guys?

Street Fighter LTD you fairly nailed it, corner power and reliability is the key factor, she will only be used for local fun and maybe to show off at the Mann TT'S next year. The frame is all ready braced and strengthened to rid frame flex so i don't have to worry to much about hard throttle out of a tight roundabout. I have all ready ticked about 80% of the points you have mentioned.

What i would really like to know is what bearings in the lower end should be replace if not all of them bar the crank.

kzstreetfighter71 wrote: What i would really like to know is what bearings in the lower end should be replace if not all of them bar the crank.

Frankly , I have never had to replace any bearings in my motor , and it sees a whole lot more abuse that yours
BUT You should always check them while cases are split. Even better is check for signs while still running , and while out of frame before cases are split .
Subtle ticks are odd feel while spinning shafts are indicators among other things
I also put a APE clutch pusher bearing in my bike early on and it is just another thing to keep all working fine . ( cheap too )
Looking forward to pictures in your area .My family tree is rooted in Mayo
Dave

Ah nice, i am on the Galway Mayo border and im from Clare, these are all my back yard, up as far as Sligo. Ill be putting the full build up and ill throw in a few photos of my local trips in there as well, if you know the town in Mayo ill swing buy and take a few photos. Thanks for the advice and be safe mate!

kzstreetfighter71 wrote: This bike is far from stock and it was fairly butchered when i got it, the owner had tried to "bobber it" thank the stars he didn't cut too much off the frame but he made a good job of cutting enough off. iI own a roadstar 1600, its my daily, iv been to the top of the Arctic circle on her via Norway and most of Europe on her, she is steady as a house foundation but lacks the...fun factor. Iv ridden in Japan, States, Thailand and India, so id like to think i know what i want from a bike in most conditions and road types. The roads where i am from are as fun to ride as anywhere on the planet but to enjoy them you need a bike that can handle and pull out of a corner quick, im not looking to race or break laws as im 1 year from 50, i just want solid smooth power that i can rely, i want parts the and a set up that i can build on in the future. The one thing iv learned is do it right the first time and it will save you heart ace and money. The smallest bore of any quality piston set i could find was Wossner and i just wont settle for anything that will have to be replace later if needs be And i do appreciate the advice about the APE 650ed, i was thinking that was a swap that might be worth while.

In a way you are looking at this backwards. I don't think anyone can guarantee that you won't have to take your engine apart again no matter what you put in it. I put a 71mm kit in mine because I didn't want to jump up to 72mm and take away the possibility of getting one more re-bore from the sleeves if necessary. Had I have known about the kit Scirocco mentioned I might have gone that way instead, but I didn't have that information at the time. I don't ride my '77 KZ-1000 like a 2020 sport bike for obvious reasons (you can't make a silk purse out of a sows ear) but it does reasonably well on curvy roads for what it is. All it takes is a couple of seemingly quick counter steers to bring you back to reality in how a mid 70s motorcycle lacks in the handling department compared to bikes of today. Good luck with your project.
Rick H.

Thanks Rick, im with you on all of that, that's why i would prefer to bore to the lowest mm but with a quality piston brand, one i can trust and not second guess after the fact, like you i would like to leave a bit of meat on the bone of the sleeves. Ill look into that German brand, iv never heard of them before but a look is free right? Thanks for the advice and be safe!

Besides bracing, have you done any suspension, brake or chassis improvements? Thats where Id toss my money at. Besides +1 on the front sprocket, the stock engine is great.

She is a full on Gsxr 1000 mono shock conversion with Gsxr USD forks, the money has been well and truely been spent on that side of things in fact im hopefully getting my new billet yokes from a machinist in the UK in the coming weeks. I just want to match the power to the performance if i can. Below photo is her on her original build in 2010.

Ill start a new build thread in the coming weeks as soon as i have a few parts back here, it may be a slow boil build, iv no intention of having her road ready until spring next year.