Thanks for the pointers. The cover took a bit of fiddling to remove, and honestly, I couldn't say exactly what the right motion was to get it to come clear but when it did it slipped past the chain tensioner with ease. The clearance on all 4 intakes was too loose (around .007") and the exhaust were both too tight (around .004").
Intakes are now set to where a .004" feeler gauge fits, but will not let .005" pass through. Exhausts now fit an .006" but too tight for an .007".
Time ran out last night to finish, so tonight it will get all closed up again and then synch the carbs. I don't think it was out of spec far enough to make any noticeable difference in how it runs but to paraphrase Forrest Gump it is "one less thing to worry about".
Living large by going small.
'86 Rebel 450
Those that have come and gone:
'74 Moto Guzzi 850T • '82 Yamaha Seca 750 • '85 Honda Rebel 250 • '99 Honda VFR 800 • '05 Suzuki AN650 • '05 • Yamaha V-Star 650 • '07 Suzuki AN650 • '07 Moto Guzzi Breva 750