Hi, everything seems ready on my bike for re-assembly... but I did not notice when I removed the 8 cam holder bolts that two of them are longer than the other 6.
Where should the two longer ones be refitted. Only one seems to screw down all the way but the other 7 holes do not seem to readily take the remaining longer bolt.

Any one know which bolt hole the two long bolts should go into?

 

I don't remember but.... If you take all the bolts out, and just set them in the holes and look at them, some of them (probably 2) are going to be setting lower than the rest, that is where the long bolts go. When arranged properly, they should all have about the same amount of dimension to the head bolt seat.

 

What durielk said is spot on when placed in the holes you can tell as before tightening all should protrude the same, if your cam chain has stretched your marks won't be text book perfect, time the exhaust cam and count the pins.

 

They virtually always go in the holes beneath which the locating bushings are placed. The thread is lower than the others. I agree though, put all the bolts in and they should be near equal before tightening. If any stick up about 1/4" above the others there will be another that will be too low, swap them.

Just always think when reassembling or disassembling. If something seems wrong or is different enough to get your attention, make sure everything is right. Odds are there is something you are missing. If a part does not come off easily, look around, make sure every fastener has been removed. If a part does not mate up correctly, like the cam cap not seating all around flat to the head mating surface, figure out why. If it requires more than a tap from a screwdriver handle or light tap from a plastic mallet odds are if you tighten things down you might break the cap. I know some KLX650 owners have had that happen when things don't line up.

Remember when doing mechanical work - you can never be too careful and care saves money.

 

Thanks everyone for the good tips; a sticky site post offers a link to the manual which shows the two longer bolt hole locations and the order of torque as well.

Back on track!