Newbie KH500 rebuild

[Huge]

So, having lurked around in the shadows of this website for too many years, I’ve decided to come out and declare my long-term KH500 restoration project..
The real reason is that despite owning a pile of bits for 30+ years, I’ve never rebuilt any motorbike so I need help!
I bought the bike in (ahem) 1984. This is what it looked like back then (you can date the picture from my wife’s hair..).

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As usual, it was pretty much all there, except of course for the airbox.. When I got the bike, it didn’t actually run. It did fire and show willing, but I’ve never ridden it!
Pretty sure it’s a genuine UK bike. Registration is PMV480R. Mileage on the speedo is only about 6K, but I suspect it’s done more.
For the restoration, I’m not planning a concours job, but will update a few components here and there to focus on rideability. I want to bike to look period, so no modern forks etc..
Over the past few months, I’ve stripped the engine and had the crank rebuilt by Gary, who’s also given me loads of advice and support – much appreciated!
I’m getting parts ready for the engine rebuild, but there’s a couple of things to check out before I proceed. When I stripped the engine, it all looked pretty good, except that the middle gear selectors was burred, as per the pic. The other two look fine, but this one isn’t. Any ideas what caused this and do I just replace it? Or, do I need to find out the root cause and fix that too? The mark on the selector is 'T7'.

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Thanks

[Wolfie]

Welcome in at last Huge..

You should look for the cause of that burring on the fork, it's probably worn dogs or the sliding gear loose (twisting) on the shaft, replace the fork if you can but that one looks to be still usable if the cause is resolved.

Measure the clearance from the fork to the sides of the gear with feeler gauges then refer to either the manual or Mraxl.

Good luck with the resto..

[SAM]

Welcome.
Yes UK KH500 first registered 23/9/76 tax due 1/12/79! Red.

[Kezsam1]

The little pins that are on the case's were pressed right In on my 400 and caused the same thing they can be pressed out again but need drilling from behind and then some plastic metal to fill the case

[Olde Coney]

Welcome to the asylum Huge..looking forward to seeing more pics/reports as your resto progresses

[Doctorpayday]

HOWDY

Not far away from you and also a KH500 owner, I can recommend you to my special needs group, if that helps.

If you are missing any parts contact me and I will chuckle.

I do have some of the airbox though.

Doc

[Huge]

Thank you all for the warm welcomes - and the advice.

I think 'special needs' sums this project up quite nicely!
My coping mechanism is self medication with red wine

I've taken quite a few pictures so far, especially of the engine strip down, so I will put some up soon and keep the thread running.

cheers
Huge