Prepare the tools
Let's prepare the tools for the maintenance yourself.　Although there are tools on stock the bike, It seems to use for emergency condition tools on go out.　I think you should prepare the tools for keeping the condition your bike.　The tools are not cheap things so that you would be bought one step by step.　I introduce my tools for the W650 maintenance.
	Picture shown ＋screw drivers and −screw drivers.　I have three sizes for ＋screws No.1・No.2・No.3,　Although No.1 size does not use frequently, No.2 screw is useful one.　No.3 mainly use for removing the side cover under the seat.　The fitting with screws are important, you should choose optimal ＋screw driver. 　About −screw drivers is not necessary to arrange various kinds.　The exchanging the mainjet work suit on the No.2 size.
	I bought 8mm 10mm 12mm 14mm 17mm 19mm 27mm ring wrenches are enough to maintain W650.　27mm wrench use to axle shaft nut for the rear wheel.　It needs for adjustment chain tension and removing the rear wheel.　The photograph is KTC(Kyoto Kikai Kougu) tools.
	The combination wrenches size are prepared as same as ring wrenches.　These wrenches are taken the throttle wire adjustment, clutch wire adjustment and etc.　Generally it is made shorter than ring wrenches.　Left wrenches made by FACOM in French.
	There are swivel handle, slide bar, ratchet wrench, extension bar (long and short), 8mm 10mm 12mm 14mm 17mm 19mm socket set, 16mm spark plug socket, 12mm hexagon screw (2piece) and 5mm hexagon screw.　12mm hexagon screw is used for front axle shaft.　If the spark plug socket has magnetic processing is convenience for the work.　I think the 3/8" socket tools easy to use for bike maintenance.
	The hexagon key wrench set, mini ratchet, spoke wrench, hook wrench. There are many places to use the hexagon screws in W650, hexagon key wrench are necessaries.
	3/8" square drive low torque applications and easy to adjust. Upper one for 9kg-m, lower one for 4.5kg-m.　It is important things to tighten the screws correct torque, I believe that the torque wrench should be required, just beginner needs it.
	The nipper, pliers, adjustable wrench.　The right to the second, slip joint pliers useful one is easy to apply power.
	Iron hammer and plastic hammer.
	Puncture repair kits. W650's wheel use the tire with tube as known.　We should prepare the repair kits for unexpected accident.　There are tire lever, sand paper, repair patch, rubber cement, wheel rim protectors.

Remove the fuel tank
	Let's try to remove the fuel tank.　It is a first step for a maintenance on yourself. 　The picture �@ to �I shows removing the and reassembling the fuel tank step by step.　If you have no experience this work, do not need afraid the removing work. Why don't you maintain your bike by yourself ! Removing Shift the hose ring by pliers is showing picture �@.　Attention the fuel cock position must be "ON". Remove the fuel hose and vacuum hose is showing picture �A. Push the hose using - screw driver with left hand and pull the hose right hand on simultaneously. Drawn out the 2 hoses extended from under the fuel tank, see picture �B. Remove the screws with 10mm socket wrenches as shown picture �C. Pull back and pull up the fuel tank for removing it. Reassembling Do it reverse step for the removing procedure. Set the fuel tank on chassis to assembles so that a hollow (picture �E) and a rubber lug (picture �D) may fit in.　Check the correct position it is shown picture �F.　It seems difficult to fit the hollow and the lug when the new bike, detergent is applied in order to improve a slide with fitting.　Adjust the fuel tank setting with seeing the hole as a picture �G.　Screws must be tighten with the hand as a picture �H.　After that, tighten the screw with wrenches.　Check the cables clearance with pinching the tank and chassis.　Check the left and right side �I. Finally return to the original state 4 hoses removed at the picture �A�B.

Check the spark plug
	Check the insulator indication of arrow, how the plug burn.　It burned in the light brown color is in a good state.　If your plug burned in the white color, It is thinkable your engine may be over heating. The spark plug burned condition will change depend on the your riding style, engine condition and your modifications (exhaust pipe, air filter, and etc).　In my case, It looks whiter than light brown, I always give the acceleration to my W650 at the mountain path??

Brake pad exchanging
	Easy way to exchange the brake pads, it will take about 15 minutes. �@Loosen the two bolt for fixing the brake caliper. �AWrenched open the pad clearance by flat end screw driver before removing the used pads. �BYou could find the wider of pad clearance, compare with the figure �A. �CRemove a hook pin, using tool is plier. �DYou can pull the fixing pin for pads, after that pads could be disassembled. �ECleaning the caliper, blow off the dust by air compressor and wipe off it by cloth.　Check the brake fluid leaking around the piston or some damage. �FAssemble the new pads, trace back the reverse step. �GBefore moving the motor cycle, pull the brake lever a few times until you felt the response. Check the effectiveness of a brake before riding.

Brake fluid exchanging
	The picture�@ showing DOT4 made by BP.　Service manual described the brake fluid should be used DOT4. The brake fluid easy to mix the water and if it put the painted surface such as fuel tank, will be damaged the painting color.　If fluid adhered to them, wipe off immediately with the wet cloth. 　Remove the cap as showing picture �A with screw driver.　You will find a plastic lid and a rubber lid, and those should be removed.　Put the clear tube and oil catcher can as picture�B showing.　Loosen the caliper reed valve (attached rubber cap) with 10mm wrench.　The oil catcher made from used oil can, drilled top of the cap and attach the clear tube. 　I think that removing the air in the brake line and brake fluid exchanging also same work.　 Keep to loose the caliper reed valve, and pull the brake lever.　The used brake fluid comes out from the tube, then tighten the caliper reed valve and release the brake lever.　If this method is repeated, the fluid level decrease as shown picture�C.　Add the flesh fluid to the reservoir tank.　Keep attention never empty the brake fluid in the reservoir tank, otherwise air will enter the brake line.　When the new brake fluid filled up to the brake line completely, tighten the caliper reed valve with 0.8kmg torque, and full up to the brake fluid indication of arrow in picture�C　Finally attache the plastic lid, rubber lid and outer lid with reverse step as you did on picture�A.　Tighten two screw with 0.15kgm torque. 　Before your starting the W650, be sure your safety, pull the brake lever, confirm the feelings, and check whether liquid has leaked all of the brake line.

Carburetor synchronization adjustment
	This is a screwdriver for pilot screw adjustment what I had Mr. Abura introduce. Although it is a things for adjusting the pilot screw in a carburetor, it can use also for adjustment of cylinder synchronization of twin engine W650 without removing the fuel tank. Although it is expensive 75 dollars as a screwdriver, I am sure more convenient to adjust by hand at the hot engine. The tip shape is a minus screw driver and rotate direction has changed in the right-angled direction by the same bevel gear as well as W650. A hand grip has indication of a unit at intervals of 45 degrees, and is intelligible in how rotate I did.
	This measurement instrument for measuring the breathing of the engine which could be measured the each cylinder.　Although it is expensive a tidy things with 420 - 500 dollars, made in Taiwan things could get it for about 83 dollars by yahoo auction. 　The picture shows three gages, top gage is not connected any cylinder.　Middle and bottom gages are connected right and left each cylinders.　Middle and bottom gages are indicated identical scale had been synchronized the carbonator breathing..
	Be sure of fuel tap position is PRI, otherwise fuel does not get down to the carburetor.　Usually, although a fuel tap's hose for vacuum detection is connected with the vacuum extraction nipple, this is removed and the hose of a vacuum gauge is inserted in the nipple of the photograph. Then start the engine, carbonator breathing is detected now and the needle of a vacuum gauge is made to read.
	The carburetor synchronization adjustment can be performed by using the screwdriver what I introduced top picture of this section.　Pilot screw driver can adjust the carburetor synchronization without removing a fuel tank. Adjustment is easy task, Let's get adjustment, as vacuum gauge needle shows the same value with screw driver.
Bevel gear backlash adjustment
	Since the sound similar to knock sound had come out as impression wrote. 　Backlash adjustment of bevel gear was performed. There are two bevel gear set on the right side engine, above one for working camshaft and other one for taking crank shaft rotation. You must understand which bevel gear noise louder. According to service manual, the engine must be warmed to 80℃ at oil pan. 　Before beginning work, marked to the side of nut (in order to indicate how you turn the nut) just under the screw in which the hexagon wrench of the upper photograph by paint. And a screw is loosened by the hexagon wrench and the lock nut for fixation take it loosened by the hook wrench. 　Starting the engine, when you turn the nut to fasten, you can hear the friction noise. when you loosen the nut, you can hear the gear strike noise louder. Adjustment of whether the nut for backlash adjustment is needed to disappear both noise. If adjustment finishes, the nut and the screw will be fastened in a reverse step. It must be careful for a screw to fasten too much. The service manual has described that a nut has a possibility of damaging bevel gear if 70 degrees or more are turned. Do not turn the nut more over 70 degrees. Adjustment of this task, reads a service manual and performs it, or be better to do at a motorcycle maintenance shop. Those who carry out personally need to carry out in accountability.
Exchange the jets
	By the chassis dynamo examination on October 4, it became clear that the characteristic is bad in the rotation region of 5000 or more rpms. It is a judgment that fuel-air mixture is still thin. Then, the main jet was raised at a stretch from No. 135 at No. 145. It seems that rotational growth became good as comment of a test run. Main jet exchange also got used, and when it was as long as 30 minutes, it could exchange. The next measurement is pleasure.
Valve clearance adjustment
	Valve clearance was measured in the place where mileage became 7700km.　Then, seven valves place were over the regulation value currently written to the manual.　I bought seven shims (approx. 4.5dollar per each) and combined variously to adjust as shown in a left table. It seems that the mechanical noise decreased a little when the engine was started.　And I had confidence that the engine get a improvement could be rotate up to rev limit. I measured valve clearance for second time at the 14839 km mileage, and result was shown above chart. Since left cylinder side was correct and well valve clearance, it adjusted only right cylinder side with I have purchased 7 shims at the last time. Although it was hard to adjust the valve clearance with 7shims, I got the best adjustment result. I am surprising that the work has resolved with each valve clearance was same completely.

The valve clearance adjustment procedure is described as follows. You should remove the fuel tank, spark plug and KCA (Kawasaki Clean Air system) devise before valve clearance adjustment work, showing such as photos. �@Remove the bolts and screws in order from screws �G to screws �@. (Bolts and screws should be removed from outside to inside) �ATake care! Do not lost two washers that are indicated with white arrows. �BEasy to remove plughole attachments after rotate the attachments such as a photograph shows. �CWhen you done until the step �B, The cam cover could be removed at last. The way to remove the cover, follow the green arrow direction in the photograph. �DNext step, remove the crank case cap A and timing hole cap B. �EWhen I unscrew the crank case cap and timing hole cap, I use with the cloth in order to avoid the damage to the caps. Please refer to photo. �FYou will find the TDC (Top Dead Center) mark into the timing hole, when the crank is rotated in counter clockwise direction by 17mm socket wrench. �GPhotograph shows rocker arm position in the TDC. �HPhotograph shows rocker arm push the exhaust valve. To find TDC timing, turn the engine over counter clockwise at the crank pulley nut until you align the nick in the timing hole, while turning crank pulley nut you will see the inlet rocker arm move the up to bottom in repeat, the TDC mark appear into the timing hole after rising inlet rocker arm, aligned the nick is just in TDC timing and valve clearance adjustment point. W650 was designed 360 degrees crank timing as parallel twin engine, TDC timing will be appeared on each cylinder by turns at intervals of 360 degrees. If you find TDC of left cylinder at first, you will be able to find other cylinder TDC timing after just one turn (360 degrees) the crank pulley nut. �IIf valve clearance was out of order, shim should be changed to keep within the limits of a regulation value. To change the shim, shift the rocker arm to out side by your finger and pickup it by tweezers. �JThis is a shim, and small. Measure the thickness of shim by micrometer (But I have no them, I measure it by slide calipers). After that, Clearance could be calculated due to suit regulation value. Using more thickness shim makes clearance become decrease. Using less thickness shim makes clearance become increase. Measure again the valve clearance by thickness gage to confirm whether value is right (refer top of photograph in this section) after setting the appropriate shim. Assemble the cam cover, bevel gear cover, plughole attachments, spark plugs and etc with reverse step, after the valve clearance adjustment work was finished. The screw of cam cover should be tightened little by little from screw �@ to screw �E in the photograph �@. Bevel gear cover screws and spark plughole attachment screws are not required hard tighten.

Fork oil exchanging
This time I tried fork oil exchanging.　At first remove the front wheel and remove the front fork from a chassis. The used oil drained and 343ml fresh oil added. When the fork is disassembled completely, oil is 400ml needed.　My W650 had milage in 9000km, I did not think that oil was dirty like this. 　I also made a woody stand for lifting up the front wheel is good fitting and stable.

Fork oil seal check
	After rain riding or washing the bike, I always care about rust occasion.　I believe that it should be avoided things is that rust occasion onto the front forks.　This time I checked it on front fork and oil seal (refer arrow B on picture �C). �@Turned over the fork boots, dust seal "A" will be shown. �AStick into the gap between dust seal and front fork outer tube with use the scraper.　That work have to pay careful attention never damage to the dust seal. �BTo avoid damage to the seal, lift up the dust seal with use flat screw driver. �CAfter lifted up the dust seal, I could see the fork oil seal "B".　Checking the scratch or rust occasion around the front forks.　If you find rust on the fork or a seal ring or a snap ring for fixing oil seal, clean them up completely and lubricate with grease.　Unfortunately, when you find folk oil leaking, you must be changing the fork oil seal.
Tire Remove
	After removing wheel the chassis, continue to remove the air valve with screw driver like left picture. See air valve detail.
	Fall off the tire from rim, this work is difficult only using tire lever. Push the tire lever to center of rim like belows picture. Front wheel is easy, but rear is too difficult. I use two tire lever to fall off the tire.
	After fall off the tire from rim, I can remove the tire from rim with using tire lever step by step. It was hard work. 　I should adjust the location of the valve�@ and circle mark�A and should set the tire rotation direction of the arrow�B.
Battery Exchanging
	Remove the saddle seat and left side panel before removing battery and remove the junction box under the saddle seat. At first pull up the lid the allows a and b. Then battery terminal will appear like a photo 2. 　Keep the removing negative terminal at first and be sure off the ground line from the negative terminal (never touch it), then remove the positive terminal. 　Remove the igniter mount due to unscrew the e and d bolts shown at the photo 3. Pull the igniter mount carefully to the wires. After that you can remove the battery. 　New battery reassembling procedure will be trace back the removing procedure. Battery terminal screw must be ensure the tighten, if the terminal screw loosen, miss firing might be occurred while you ride the W650.

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