Engine Cover Gasket Set Installation Instructions

Compatible Models:

• KLX250 (1994-2016)
• KLX250R (1993-1997)
• KLX250S (2009-2014)
• KLX300 (1997-2007)

Tools Needed:

1. Socket set or wrenches (size may vary depending on your specific model)
2. Screwdriver (flathead and Phillips)
3. Torque wrench
4. Gasket scraper or razor blade
   5.Clean cloth or paper towels
5. Engine oil for lubrication
6. Safety goggles and gloves

Installation Steps:

1. Preparation:

   • Ensure the motorcycle is on a stable surface and the engine is cool.
   • Disconnect the negative terminal from the battery to prevent electrical issues.

2. Remove Engine Cover:

   • Using the socket set or wrenches, carefully remove the bolts securing the engine cover.
   • Gently pry the cover off, being cautious not to damage any surrounding components.

3. Clean the Surface:

   • Use a gasket scraper or razor blade to remove any remnants of the old gasket from the engine cover and the engine block.
   • Wipe the surface clean with a cloth or paper towel to ensure a smooth sealing surface.

4. Apply the New Gasket:

   • Place the new gasket onto the engine cover, ensuring it aligns correctly with all holes and edges.
   • Optionally, apply a thin layer of engine oil to the gasket for better sealing and ease of installation.

5. Reinstall Engine Cover:

   • Carefully position the engine cover back onto the engine, ensuring the gasket stays in place.
   • Hand-tighten the bolts in a crisscross pattern to ensure even pressure distribution.

6. Torque the Bolts:

   • Using a torque wrench, tighten the bolts to the manufacturer’s specified torque setting. Refer to your motorcycle’s service manual for the correct torque values.

7. Reconnect Battery and Test:

   • Reconnect the negative terminal of the battery.
   • Start the engine and check for any oil leaks around the new gasket.

8. Final Inspection:

   • After testing, perform a visual inspection to ensure everything is sealed correctly.

Conclusion:
Congratulations! You have successfully installed the Engine Cover Gasket Set. This repair should enhance your engine's performance and longevity, making your riding experience smoother and more enjoyable. Remember to keep an eye on the gasket for any signs of wear and address any issues promptly. Happy riding!