I did the valves on my KLR according to the guides at KLR.net The advice there was to torque the caps much lower than the manual says to avoid breaking them.
1. Do people reduce the torque on these bolts? If so to what?
2. Has anyone replaced the valve cover gasket or the two inner gaskets?
There is a complete thread on this in the How To Forum, to answer your question, I torqued according to the specs in the manual, I can tell you they were way over torqued removing them. As to breaking them, there are exhaust and intake, don't mix them. As to breaking them, the problem comes in when a lack of skill and a lack of patience is combined. These caps are precision machined to a very close tolerance, if they don't go on easily
, stop and remove the cap, probably not going on squarely , peoplke have been known to put the bolts in and start torquing the bolts with a crooked cap, next thing is snap
. Second thing to remember is to tighten in a X pattern, use a reduced setting , 60%, 80% 100%. It is explained in the How To thread. And the gaskets, read the thread, to my knowledge, no one ever replaced the gaskets. You will need some permatex or other sealant as described in that thread. I have done it and many others, Fasteddiecopeman is probably on the 5th or 6th time doing this.