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Discussion Starter · #1 ·
Hi-

Preparing to do the valve check on my 2015 650. Has a little over 22k miles on it, I figured this winter would be a good time to rip the bike apart to do this. So I'm looking for advice on where to order parts from. At minimum I figure I need:
-new valve cover gasket
-new spark plugs (since ripping the bike apart to get to them is such a pain)
-new air filter (same as previous)
-shim kit?

Anything else? Who's your preferred online parts store?

Thanks,

dm
 

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NGK CR9EIA-9 NGK 6289 Spark Plug | RockAuto

You will typically only need shims that are between about 2.80 mm to 3.10 mm. They usually need to be slightly thinner than original. I thinned and switched some shims around, to set all my inlet valves' clearances at 0.18 mm, and exhausts at 0.26 mm at middle of spec range. I used wet fine emery cloth on a flat wood surface to thin some of my original shims.

If you're not up to the task, you can get 7.48 mm diameter shims (same as Versys) in 0.025 mm increments (instead of only 0.050 mm increments) in 2.50 mm to 3.50 mm thicknesses from your Kawasaki or Suzuki dealer.

Suzuki 2004-2005 RM-Z250 shims $8.47
Kawasaki 2006-2011 KX-250F shims $8.96
(Versys shims 0.050 mm increments $11.78)

Shim ------- Suzuki # ----- Kawasaki #

2.800mm - K9218-00179 - 92180-0179
2.825mm - K9218-00180 - 92180-0180
2.850mm - K9218-00181 - 92180-0181
2.875mm - K9218-00182 - 92180-0182
2.900mm - K9218-00183 - 92180-0183
2.925mm - K9218-00184 - 92180-0184
2.950mm - K9218-00185 - 92180-0185
2.975mm - K9218-00186 - 92180-0186
3.000mm - K9218-00187 - 92180-0187
3.025mm - K9218-00188 - 92180-0188
3.050mm - K9218-00189 - 92180-0189
3.075mm - K9218-00190 - 92180-0190
3.100mm - K9218-00191 - 92180-0191
 

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As the clearances DECREASE (the valves TIGHTEN up), a LOT of us just 'sand' the shims to the measurement necessary to end up w/ the clearance at the WIDE end of the specifications, so you wouldn't need to have a "shim-kit". For instance my SERVICE MANUAL gives the clearances as: EX - .0087 to .0122"; IN - .0059 to .0083", so I would GENTLY sand the shims to attain .0122" for exhaust, .0083" intake.

Once that's done, altho' you SHOULD check them regularly, they will probably stay w/in limits for quite awhile, before you need to "do them" again.
 

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The first time I 'checked the valves' in my '08 was at 20,429 miles, and I ordered the appropriate shims from the dealer. When they called that they had arrived, I went over c/w my dial-caliper to check them. Near as I can remember (this was back in Dec 2010!) - NONE of them were the advertised size, so the mechanic let me go thru his "box of used shims", where I was able to get VERY close to what I needed, by replacing ALL FOUR exhausts, and ONLY ONE intake shim.

The NEXT time I checked them at 42,853 miles in April 2013, they were ALL OK, w/ VERY SLIGHT tightening on two exhaust valves (but STILL w/in limits), so I left them alone.

The THIRD valve-check came in January '17 at 68,680 miles. ALL four intake valves were the same as the previous check (NO changes), while I 'sanded' all four exhaust shims, but only SLIGHTLY, (MAX change was from .30mm to .25mm, while the SPECIFICATION LIMITS are .22 to .31mm!

(y)(y)

:cool:
 

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Great idea on sanding the shims! I never would have thought of that.

And yeah, they tighten up. I remember the old ninja 600 my buddy had that wouln't start when it was cold because the valves were hung open from them tightening up. A valve adjustment later and it fired right up no problem.
 

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I used 200 and 300 grit carbide sand paper. Explanation is in my post:


 

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I pretty much use 180 (close to the same grit as onewizard), because I had it onhand.

(y)(y)
 

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Hi-

Preparing to do the valve check on my 2015 650. Has a little over 22k miles on it, I figured this winter would be a good time to rip the bike apart to do this. So I'm looking for advice on where to order parts from. At minimum I figure I need:
-new valve cover gasket
-new spark plugs (since ripping the bike apart to get to them is such a pain)
-new air filter (same as previous)
-shim kit?

Anything else? Who's your preferred online parts store?

Thanks,

dm
I use Babbits online .... or is it Babbetts?
 

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Discussion Starter · #12 ·
Hi-

I'm hoping someone here can help me, I am attempting to do the valve check on my 2015 Versys 650. I'm following Fast Eddie's "Valve Adjustment Procedure" pdf file on how to do this, but am stuck at removing the airbox. At page 9 it says
Organism Font Water History Soil


But I can't really figure out which bolt or screw to remove. I have the TechSpark manual, but despite claiming it is good for Gen3 the picture it shows is obviously for an earlier Versys. Here is what I see on the LH side of the airbox:

Motor vehicle Hood Vehicle Automotive design Automotive exterior


Two blue painted 8mm bolts, and way back there to the right of the upper blue painted bolt appears to be an allen headed bolt of some size. Totally inaccessible with any tools that I have unless I can remove other stuff to get to it. I'm hoping that's not the correct bolt to remove, but maybe it is? Which one are the throttle body clamp bolts, and is there any harm to removing them?

Thanks!

-dm
 

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It is the Allen head bolt, and it should be at least 4mm... Give the entire engine and everything above it a good wash before you start working on it.
 

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I have a set of "T-handle" allen-wrenches in BC, and by memory - the shank is about 4" long, for working w/ THAT bolt.
 

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Discussion Starter · #18 ·
Hi-

Thanks to everyone who responded last night, I was able to get the rest of the disassembly done this afternoon. Total was about 6 hours to getting the shims exposed, not counting time spent driving all over town looking for some special tools.

Anyway, now I am confused about where to set the cam lobes to measure cylinder #1 shims. I found that the timing marks that seem correct for my bike is the "1|T", as shown in the SM, not the "1 over T" everyone says is correct. If I use "1 over T", the exhaust cam lobes are compressing the valves. "1|T" looks more correct, with the cam lobes in the 10 and 2 o'clock positions as shown. Have I got this right? Or am I screwing up? In this position, all 4 shims for #1 are at spec min. clearance.
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Thanks!

dm
 

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I will post a photo but here is my thread-actually scroll down in the thread below, go to post #8, watch for a screen shot of the cam shaft sync position from the manual, directly below is a photo and explanation, the service manual has been wrong for 3 generations, one section is correct, the other section has a typo.
 

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Discussion Starter · #20 ·
Hi-

Thanks to all the help that I've gotten, I managed to get the valve cover off today and start checking the clearances on m y 2015 V650. I'm a bit confused because on this forum I've read that the timing mark should be "1 over T" when checking cylinder 1, but what I found was that in that position the exhaust cam lobes were on the exhaust shims. If I moved to the "1|T" position, the intake and exhaust lobes are in the "10 and 2 o'clock" position, and I was able to measure the clearance of all 4 valves, with them being right at the spec. min. So now I'm wondering if I am doing this correctly? These pictures show what I've got:

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Thanks!

-dm
 
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