I dont have as much experience with those guides as some here, but you should just be able to snap that back in from the top. It kind of sits in a detent down there by the drive sprocket. Maybe you can snap it back in after the cylinder is installed??

 

Yes, you can put the guide back after the cylinder is installed, not so difficult. I have done it several times. Try to use a torch to see better where it goes.

 

I'm pretty stuck here. Ive inserted the guide back in but it still comes out as easy as it does slide in. The manual doesn't really show you how to insert it correctly.

When I do slide it in, it rests nicely but has some play. It doesn't take much force to come out. I'm scared to bolt the whole top end back up because of this.

 

I think the chain tension holds it in?

 

The thing is, the part of the guide that came out is opposite of where the tensioner goes in.

 

Never had one out, but if it slides down in and stops, the cam drive chain could only pull down on it due to the direction of rotation.

 

IIRC, the end of the guide has a step/notch that rests between the case and a retainer plate. It should just slide in and bottom out. I had some challenge getting it to fit properly.

 

Ok so this cam chain guide Issue delayed my progress a little but yesterday I took off the engine cover to see if the guide was sitting correctly. A little much but it's all I could have done to confirm if the guide was sitting flush even with the little "play" it had. Turns out I did insert it correctly. Now I have to replace some gaskets. ___ smh.

On that note ... Has anyone ever used a Caltric Gasket? They're $15-20 cheaper than OEM. click me

Anyways, peep these images so you can see where the guide is sitting.

 

I finally got around to swapping the engines yesterday and after about 9 hours of work, tacos and beer, my now KLX351 fired up first try. I must say, it felt pretty damn good.

I didn't get it take her out for a test run because I'm waiting on a new chain but will check back in when I do.

I want to thank y'all here on kawasakiforums.com for the help and support through this build. It was my first time rebuilding a top end and I wouldn't have done it without y'all.