This is straight from the service manual with some added info. If you have any questions email me and I can help. Have done this many times on my ride. You will need the following: metric socket set, allen wrench set, thickness gauges, ratchet, extension, penny & nickel, pliers, screw driver(phillips tip), 10mm open or boxed in wrench, and torque wrench (if you want to do it to specs)

Valve Clearance Adjustment
1. should be made with the engine cool, at room temperature.
2. Whe the valve clearance is to be measured or adjusted, the piston must be at Top Dead Center(TDC) on the compression stroke.

1. Remove
-meter assembly = 3 screws, unscrew the tripometer cable and two cable wirings.
-fuel tank and seat =two screws close to the seat. BE SURE TO CLOSE THE FUEL PETCOCK BEFORE REMOVING ANY HOSES FROM THE TANK!!
2. Remove
-Carborator assembly = see below for instructions
A.Air filter case assembly = the air filter housing
B.Air Duct = big black canister under tank
C.Cylinder Head Breather Hose = black hose connected to the Air Duct
D.Throttle position sensor lead =connects to top of carb at the
end closest to the seat.
E.Thermo switch lead = just unclip it
F.Fuel hose = on the left side of the carb
G.this one not in the book but I know it has to be done. a hose that goes from the carb to a plug that is behind the air filter housing. just pull if off the plug. nothing will leak out it is ok.
H.Carburator assembly = held on by screw on bottom-two
I.Starter Cable = choke cable
J.Throttle cables
K.Cover =black and aluminum(i think)sheet. just pull it up and off

For installation, reverse the removal procedure.

3. Disconnect:
-spark plug caps
4. Remove
-spark plugs
5. Remove
-Ignition coil = rear one. has two screws. has spark plug wire connected to it
6. Remove Cylinder head covers = 4 screws on each. then on the lower half the front has 4 more bolts and the rear has 2 bolts. lots of luck and patience gettting them off.
7. Remove
-Tappet covers = all of these are a grey color. located on the front and rear of each cylinder. each have two bolts 10mm.
8. Remove
-camshaft sprocket covers = there are 2 of these. the rear cylinder camshaft sprocker cover is on the left side(as if riding) and the front cyclinder CSC is on the right side. 2 bolts holding them on.
9. Remove
-timing plug = located on the crankcase cover(left side of bike. closer to the rear of the than the place where you fill the bike with engin oil. circular with a slot big enough for a penny)
-straight plug = located just under the timing plug. it is bigger and has a slot big enough for a nickel.
I use a penny and nickel to remove them. I hold each peice of currency with a pair of pliers and use them as a screw driver tip.
10. Measure Valve Clearance
-valve clearance
out of specification - adjust
Valve clearance (cold)
intake valves 0.07 to 0.12mm (0.003 to 0.005in)
exhaust valves 0.12 to 0.17mm (0.003 to 0.005in)

MEASURING STEPS
-turn the crankshaft clockwise with a socket and ratchet with extension.(crankshaft access through straight plug)
-align the camshaft sprocket mark with the stationary pointer on the cylinder head.(going back to when you removed thecamshaft sprocket covers. the sprocket inside that has a chain around it also has a mark almost like what a punch would make. At the top of the cylinder
head is the stationary pointer.)
When the mark is aligned with the pointer, the position is at Top Dead Center(TDC).
-Check the front/rear cylinder timing mark on the rotor. If necessary, turn the crankshaft to align the timing mark(look at A and B below for what to look for) with the pointer(a gap in the upper right hand corner of the straight plug)on the AC magneto cover.(you can see the marks on the rotor through the timing plug. ALWAYS TURN THE CRANKSHAFT CLOCKWISE!)
A. for rear cylinder("T1" mark)
B. for front cylinder ("1" mark)

-Measure the valve clearance using a thickness gauge.
11. Adjust
-valve clearance
Adjustment steps:
-loosen the locknut
-insert a thickness gauge between the valve top and the adjuster.
-turn the adjuster in or out with an allen wrench until the specified clearance is obtained.
TURNING IN: valve clearance is decreased
TURNING OUT: valve clearance is increased
-hold the adjuster to prevent it from moving and tighten the locknut.
locknut: 14Nm(10 ft lbs)
-measure the valve clearance again.
-if the clearance is still incorrect, repeat all the clearance adjustment steps until the specified clearance is obtained.
12. Install
-all removed parts in reverse order of their dissassembly.
13. Install
-camshaft sprocket covers 10Nm(7.2 ft lbs)
-tappet covers 10Nm( 7.2 ft lbs)
-cyclinder head cover 10Nm(7.2 ft lbs)
-spark plugs 18Nm (13 ft lbs)

IF you have any problem please ask. I can help you with almost any problem you have with this proceedure.

Travis Howard
Kailua, HI
'00 650 Classic

Added notes from Bill Hamm

Some notes about this procedure :)

1. Remove
-meter assembly = 3 screws, unscrew the tripometer cable and two cable wirings. << helps to remove the speedo cable from front wheel too, can pull up on the cable then at the speedo and gives you more room to work.

2. Remove
-Carborator assembly = see below for instructions
H.Carburator assembly = held on by screw on bottom-two
I.Starter Cable = choke cable
J.Throttle cables << Choke cable and throttle cables have to be removed first to get the carbs off.

K.Cover =black and aluminum(i think)sheet. just pull it up and off >>
Pull off and discard, no one's ever figured out what it's for, and it runs great without it :)

6. Remove Cylinder head covers = 4 screws on each. then on the lower half the front has 4 more bolts and the rear has 2 bolts. lots of luck and patience gettting them off. << found a couple tricks, one cut the front bottom cover to match the rear one, make it U shaped with opening at the front, makes it alot easier to remove/install. New thing, cut the top covers in half front to back, makes removal and install simple and you have to look really carefully to see the cut :)

-straight plug = located just under the timing plug. it is bigger and has a slot big enough for a nickel. << put 2 nickles in a vice grip, pulls them right out :)

10. Measure Valve Clearance
-valve clearance
out of specification - adjust
Valve clearance (cold)
intake valves 0.07 to 0.12mm (0.003 to 0.005in)
exhaust valves 0.12 to 0.17mm (0.003 to 0.005in) << the inch spec. is incorrect in the manual, the metric spec is correct.

from: tHe_mAd_rUSSIAn (THE_MAD_RSHN)