Can't wait to see more!

 

Quick update:

I will post some pictures later but I just wanted to thank everyone for their input. It's not complete but last night I managed to get the head installed and properly torqued, the cams installed and properly timed, and the head cover on. I also checked my valve clearance and they were all at the low end of the spec so I'm very happy. The biggest problem I had was getting the exhaust cam in. This was due to the fact that the cam chain guide on that side was not all the way down into the lower unit. It seemed normal but something just wasn't right and the cam wouldn't sit all the way down without the sprocket touching the cam chain guide. It was driving me crazy. Finally I took some pliers and pinched the bottom end of the chain guide just enough to flatten it a bit and quickly moved it into position. It finally went all the way down and the rubber re-expanded into place.

After that it all fell into place. I managed to connect everything else back up (oil tube, coolant hoses, brackets, etc) except the exhaust and carb. I'm waiting for some stuff in the mail to do my carb breather mod.

BTW FingerMullet - I actually did not know that you could be 180 degrees out on the TDC, but of course I could see the piston at that point and I knew it was at the top. After the head was on and I couldn't see the piston I found out exactly what you were talking about. After rotating the crank to TDC, I tried checking my valves but they was NO space between the cam lobe and valve bucket. I thought I must have done something wrong. I was starting to get kind of pissed. After a while I remembered your post and I rotated the crank again another 180 degrees and this time my valve clearance was perfect. Thanks for that info it was VERY helpful and very timely.

I probably won't finish up this project until next week since I'm waiting on parts and I have to work this weekend but it's getting close. I can't wait.

 

You're so close to firing up the 351 cubic centimeters of joy

 

Yeah and I'm trying to talk my wife into letting me buy a 4 wheeler... I just need to find the right one :-)

 

4-Wheeler???...c'mon...those are for people who can't ride dirt bikes!

 

Got the 132 main jet put into the carb tonight along with moving the needle to the fourth notch. Got the carb installed and the header/muffler put back on. All I need now is to put a cap on the carb where the smog tube used to hook up and put the breather mod in. Then it's just a matter of putting the tank, seat, shrouds back on, filling the fluids, and firing it up!

 

What kind of break-in are you thinking?

 

Glad you got it .... see a boater can help you F'n biker's out

Just to be clear .... on the klx when at TDC the front exhaust cam lobes point at the front tire and the rear intake cam lobes point at the rear tire.....if the lobes are pointing toward one another... you are 180 out

Yammi outboards are the same way......well except the motor is inverted

 

I can verify this is true!

 

It's alive!!

Finished putting it back together tonight. I filled up the oil and the coolant, checked everything over one last time, and turne the key on.

It started up immediately. (normal use of the choke). It was dark outside as I was letting it warm up (with the choke on) and I noticed the header started to glow. It's never done that. As soon as I was able to back the choke off, it cooled right down. Still, it's a little concerning that there was that much heat generated. I hope it doesn't mean something is wrong.

I let it warm up for about 10 minutes then took it up and down the driveway just once. I didn't get it above 3000 rpm so I can't really say how much more power there is but I'll let you know after a couple of heat cycles.

Thanks for all the help. I didn't really take any pictures putting it back together, I just reversed the disassembly. It seems ok so far!