Install the new valve shim(s) and reassemble the camshafts in the reverse order of disassembly.
Make sure that the (T) mark in the inspection hole hasn’t moved a.
The cam sprocket timing marks must be aligned with the cylinder head gasket mating surface.
Remove the cam chain tensioner cap bolt using a 12 mm wrench along with the washer and spring.
Inspect the cam chain tensioner for wear and damage.
Reset the cam chain tensioner by pushing down on the spring loaded ratchet stopper and collapse the adjuster all the way in.
Replace the cam chain adjuster gasket and install the adjuster making sure the arrow points downwards.
Insert the two cam chain tensioner mounting bolts and tighten securely with a 10 mm socket. Torque the bolts to specification.
Cam chain adjuster bolt torque: 9.8 N-m or 7.0 ft-lb
Insert the cam chain tensioner spring. Install the cap bolt with a new sealing washer.
Tighten the cap bolt securely with a 12 mm socket. Pay special attention to the timing marks on the cam sprockets making sure they don’t move.
Clean and oil the bottom of each cam holder before installing. Make sure that the dowel pins are in position.
Before inserting the head oil pipe into the each camshaft cap check that an O-ring is present, properly positioned and in good condition. Lubricate the oil pipe with oil to prevent damage to the O-ring. Early model KLRs have banjo bolts to secure the oil pipe to the head.
Before reassembly, fill the oil pipe with engine oil to prime the pipe and avoid engine damage on startup.
Install the camshaft holders making sure that the arrows on the caps are pointing forwards. Tighten the holder bolts starting with the top left front bolt and then the bottom left rear bolt. Then tighten the right side cam holder starting at the top and then the bottom bolt. This procedure is the same for the exhaust and intake cams.
Note: Be very careful not to damage the camshaft holders as they are not available, if one is damaged the entire cylinder head must be replaced.
Tighten the camshaft holders bolts to specification.
Cam holder bolt torque: 12 N-m or 8.5 ft-lb
Tighten the cam chain tower bolts to their proper torque specification.
Cam chain tower bolt torque: 5.5 N-m or 7.0 ft-lb
Re-check the valve clearance after re-assembly. Re-adjust if necessary.
Exhaust valve clearance: .15 – .25 mm
Intake valve clearance: .10 – .20 mm
If the measurements are within specification, reinstall the valve cover using a sealing bond around the cam cutouts, this will help seal the rubber gasket and prevent an oil leak. Tighten the valve cover bolts to their proper torque specification.
Valve cover bolt torque: 7.8 N-m or 7.0 ft-lb