DL650 Valve Adjustment Notes.ZIP

This zipped Word document contains several pages of notes that I prepared after completing the first valve adjustment on my DL650. It is a compilation of suggestions from other posters and my own tips and observations. It is meant as an adjunct to the Workshop Manual, certainly not a replacement. It will be of more use to newbies than experienced wrenches.

In short, it is exactly what I wish I had been able to find, all in one spot, before I embarked on the valve adjustment. I hope it is of use to others.

The topics it covers are:
-Introduction
-Disassembly
-Radiator Removal
-Removing the Cylinder Head Covers
-Rotating the Crank
-Notes on Measurement
-Checking Valve Clearances
-Cam Chain Tensioners
-Cam Removal
-Bucket and Shim Removal
-Shim Measurement and Installation
-Parts, Tools and Supplies
-Torque Wrench
-Shim Kits

Feel free to provide feedback or ask any questions you might have.

Nick

Looks good, I just printed it out and read through it.

The only part of this job that has me concerned is the cam chain. Hate to mess that up and bend all the valves on start-up

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Roger ('07 Wee, '06 FJR (For Sale), COG 5903)

I did just that with a Honda CB500. The 650 has well marked cams and good service instructions. If carefully followed, cam timing shouldn't be a problem.

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Pat- 2007 DL650A was ridden to all 48 contiguous states. 2012 DL650A is just getting started.
Nicknames for posting ease on my part, Vee = all DL1000s. Wee = 2004-2011 DL650s. Glee = 2012+ DL650s

This will be my first "bucket type" valve adjust, done several screw and lock nut ones. This looks more interesting to say the least!

Much great info on this site though so I'm sure ya'll be able to help me out if needed

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Roger ('07 Wee, '06 FJR (For Sale), COG 5903)

Thank you for taking time to post this information!

Good job. I have 2 questions, as I am fixing to do mine and want to minimize down time by having shims available before hand. Not sure if I will be able to get them from a dealer. Since you mention that the factory installed shims all seem to be in the 1.60mm – 1.75mm range I was thinking of getting this Hot cams refill kit

HC-7150175 Includes 5 of each size 1.50, 1.55, 1.60, 1.65, 1.70, 1.75 mm shims $35.99

instead of the big kit that includes 3 of everything. Would this be a good bet? All of yours were in this range, correct?
Has anybody else had any outside this range? Please chime in. Thanks

Kevin

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Kevin

L2 DL650A The Orange Machine
K7 DL650 Hi Yo Silver R.I.P!

Kevin,

That kit would have fit my bike fine. It's relatively expensive (per shim) compared to the big kit, but it seems like the right sizes and 5 rather than 3 of each size is great. You'll need others to chime in on what sizes they've needed, but I'd say go for it.

I found it very convenient to have the shims on hand.

Nick

NTM,

Q1:Could you(or anyone else) recommend a specific brand & model of tappet feeler gauges suitable for checking the valve clearances on theDL650 ? I don’t think the standard tongue-depressor type will work. Wouldn’t the angled type with a range covering an 001” to .020” be necessary ?

Q2:Are there any dowel pins or o-rings that need to be removed when stripping the engine while performing the valve adjustment procedure ? Are there any cam bearings or bearing retainer clips under the journal holders ? I don't see any in the manual, but I want to be sure.

Q3:Is it necessary to use any particular kind of assembly lube when re-installing the cams on the DL650 ? I watched a Hot Cams installation video recently for a different bike and they had a tube of this stuff they kept putting on the cams, cam support and top of the lifter where it makes contact with the cam to 'avoid engine damage at start-up'.

Q4: They also have a break-in procedure which recommends running the engine for at least 3,000rpm for 30 minutes following re-assembly(no idling;light loads only). It should be noted that in this video they also were installing a different cam with the shims. Did you do this ?

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'06 DL650 Pearl Crystal Red

Nice writeup! Good timing, too. I'll be checking mine in another 1500 miles or so, though I expect them to be right in the middle of their ranges where I left them judging from other members experience on this site.

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"Scarlett" RED 650 K6 ~ 48K mi / Offroad Club #14
...with various wallet deflating additions.

XLonDL650,

Q1: Any feelers will work - you just need to bend them a bit with your finger as they approach the cam/tappet. You might want to shoot for Craftsman quality rather than Harbor Freight on this item. You can get fancy if you want, but definitely not needed. I do have a staight set where the tip tapers in and they are convenient, but again, not necessary. Suggest you reread my notes on using feelers though.

Q2: No dowel pins or O-Rings. There are some in the cylinder head, but you just leave them unduisturbed.

Q3: Any "ass lube" will work. I liked the look of the clear stuff in the tube in the Hot Cams video. Remember the Hot Cams video assumes you are replacing the cams, not just shims, so they are very liberally using assembly lube. I think the DL650 manual calls for something like "molybdenum oil" for this use, but I used a bit of assembly lube. Manual also tell you where to use some motor oil during reassembly.

Q4: Again, break-in is for new cams, not shims. No break-in needed here, just normal warm-up (and paranoid listening for strange noises, if you are at all like me).

Give it a go - good luck!

Nick