Are you talking about the crankshaft sprocket behind the ignition cover?
Marked by blue. It only rotates counter clock wise, not clockwise. The crankshaft rotates both, counter clock wise and clockwise.
Since the inspection hole is called the "starter inspection hole" I'm assuming that's a starter gear / starter clutch?
Anyways, the problem was a dowel pin sticking 1mm above the rest. I just hit it flush with a rubber mallet. It literally took 6 hours and 5 attempts to seat the cams to figure it out. If anyone is reading this, save yourself 6 hours and make sure all the dowels are flush to the cylinder head. My new exhaust clearances are
0.275 0.26 0.26 0.26 0.26 0.26 0.26 0.26 From
0.145, 0.15, 0.145, 0.175, 0.155, 0.145, 0.10, 0.10 mm Ex standard
: 0.24-0.32 mm IN standard
: 0.13 to 0.18 mm
I put the CCT in, it only started to click when I rotated the crankshaft clockwise 2 times, taking up the slack. Overall, I can't believe it worked!
Will post a startup video. 11k miles. I also changed the spark plugs, air filter, coolant, oil, fork seals/bushings, chain & sprocket. Also some sick tank knee grip pads.
As long as there was an actual clearance (ie - not zero) I would just keep running it, but I am a heathen compared to others here like RiversZZR. My 98 has a specified clearance on the exhaust side of 0.22-0.31mm (0.009"-.012"), so you were half of that. That isn't good, but it shouldn't be the end of the world, either.
Like I wrote in this post, I was actually using mm and my exhaust weren't tighter than 0.10, with an average of 0.15mm. Which is good considering this bike was beat the piss out with no exhaust and wheelies by the previous owner. No surprise all exhausts were out of spec and he sold it to me with 10.5k miles
Now all my clearances are 0.26mm for the exhaust. All of the intakes were already in spec at 0.15mm. I'll likely recheck clearances in 2 years. I used victor reinz german gasket stuff (grey/black) to use on the old cover gasket.
I really liked playing around with the stock CCT. I made sure to oil it some, pull it out with 'force', as well as make sure it didn't go back, etc. Seemingly solid design by Kawasaki. I won't mind a rattle even though I'm sticking with a stock exhaust + cat. I'll probably commute with the bike to uni. Insurance for me is $180 a year and reg is $80 here in California. This is my learner bike and I honestly am not too upset I got an 07 zx6r instead of 09-2012.
Thank you guys for the posts and trouble shooting. I'll post a startup video in less than 3 weeks.