SAFETY FIRST: Protective gloves and eyewear are recommended at this point.
Cylinder Head Removal
Remove the cylinder head cover. See the Valve Adjustment topic for more information.
Remove the valve train. See the Valve Train Removal topic for more information.
Removal of the cylinder head can be done with the engine in the frame. Make sure the frame and engine are clean and pay particular attention not to let parts or debris enter the engine. The following procedures are shown with the engine removed from the frame.
Remove the banjo bolt securing the oil pipe to the cylinder head using a 12 mm wrench.
Discard the two sealing washers.
There are 11 cylinder head fasteners. Remove them in descending order (11 first 1 last)
Remove the cylinder bolts in the cam chain cavity using a 10 mm socket. (Red)
Remove the Allen bolt from the exhaust side of the cylinder head using a 6 mm Allen wrench. (Blue)
Remove the two cylinder head nuts under the exhaust and intake manifolds using a 12 mm wrench. Two are for the cylinder head and two are for cylinder. (Purple)
Remove the four remaining cylinder head bolts using a 14 mm wrench. (Green)
It may be necessary to gently tap the cylinder head with a rubber mallet to break it free for removal. Be careful not to damage the cylinder head.
Lift the cylinder head from the cylinder.
Secure the cam chain so that it does not fall into the engine. A long screwdriver or a piece of wire can be used.
Pay particular attention to the placement of any dowel pins located in the cylinder head or cylinder.
Cylinder Head Installation
Clean the gasket surface of the cylinder and cylinder head using an aerosol brake cleaner and a Scotch Brite pad. Place the new head gasket on the cylinder, making sure to align it with the dowel pins.
Feed the cam chain through the opening in the cylinder head and lower the cylinder head onto the cylinder.
Install the cylinder head fasteners and torque them to specification as indicated.
Cylinder Head Torque Specifications
KLR 600 1984 – 1994
Cylinder Head Bolts (Green): 37 – 41 N-m (27 – 30 ft-lb
Cylinder and Cylinder Head Nuts (Purple): 25 N-m (18 ft-lb
Allen Bolt (Blue): 18 N-m(13 ft-lb
Cam Chain Cavity Bolts (Red): 9.8 N-m(7 ft-lb
KLR 650 and 500 1987 – 2006
Cylinder Head Bolts Initial (Green): 20 N-m (14.5 ft-lb
Cylinder Head Bolts Final (Green): 65 N-m(48 ft-lb
Cylinder and Cylinder Head Nuts (Purple): 25 N-m (18 ft-lb
Allen Bolt (Blue): 18 N-m(13 ft-lb
Cam Chain Cavity Bolts (Red): 9.8 N-m(7 ft-lb
(GREEN) Apply molybdenum disulfide grease to the threads and base of the cylinder head bolts. Install the four cylinder head bolts and torque them to specification using a crisscross pattern. Tighten the bolts evenly. Use two stages on the 650 models.
(PURPLE) Install the two cylinder head nuts under the exhaust and intake manifolds and torque them to specification.
(BLUE) Install the Allen bolt from underneath and torque it to specification.
Torque the cylinder bolts in the cam chain cavity using a 10 mm socket. (Red)
Replace both of the crush washers making sure to place one on each side of the banjo fitting.
Install the oil pipe banjo bolt, using the new sealing washers and torque the banjo bolts to specification.