Will you be doing standard size valves?
Yes, I think so. I'll probably go with the Schnitz aftermarket valves on the exhaust. Regarding going 1mm oversize on the valves, where can you get that done nowadays? I notice the M-Tech KLR650 web page ( http://www.mtechmotorcycles.com/perf...5-705-kits.htm
) no longer works - have they closed?
I'm going to preface this "how-to" by saying, know your limits with respect to your personal capabilities. I personally think most people can accomplish amazing things, but these tasks (and that's how I view them) done improperly can ruin your head... the tolerances between the valve shim buckets & bores, and the valves & valve guides are very tight. If you nick (damage) a valve seat, that will require (expensive) re-grinding... not a DIY job.
You'll notice in previous pics, the combustion chamber was already de-carboned... with valves left in. I use a small screwdriver, on which I've taken like 400 grit sandpaper and radiused the edges slightly to reduce the possibility of gouging the soft aluminum. I use sandpaper, and 3M Scotchbrite pads to finish up. Don't remove any metal - enlarging the combustion chamber reduces compression ratio.
With the combustion chamber cleaned up, time to pop the valves out. The shim & buckets should come out easily - if not, you've likely got scratching in the bucket bores (carefully dress that out with 800 grit). With the buckets removed, use an automotive valve spring compressor tool ( https://www.princessauto.com/en/deta...or/A-p8003725e
) to compress the spring, and remove the locking collets. Be careful to keep each end of the tool centered - don't let the steel compressor end touch the (easily damaged) aluminum bucket bores!
Once you've popped the valves out, next step is to block off all areas you need to protect from crud - de-carboning and porting makes a mess, and you don't want that getting in the oil passages, valve guides, etc. I roll up pieces of paper towel, and wad it in the spots needing blocking off:
Don't forget to plug the oil line orifice, and remove the rubber intake boot. I install the valve cover back on, to keep debris outta there:
Ready for de-carboning... tomorrow. Ugly job that it is.