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Shafer · March 28th, 2023, 07:08 AM

Both my baby 07’s are sick – Hitting a 4-6k rev wall

Winter work:
07 Black and 07 Blue
*stock exhaust
-New Plugs -NGK 2086 CR8HSA
-Renewed HT leads – new wire cleaned connections
-Cleaned air filter and proper oil with Belray – Uni NU-2366
-Valve adjustment
-New oil – K&N401 / T6 10w-40
-Cleaned and split carbs, dip, ultrasonic, carb spray, compressed air, copper wire – so clean!
-Replaced carb o rings with a kit
-Replaced vacuum hoses with snap clips – Tygon hose used
-Needle shim - .60mm
-No rips in diagrams, slides move and fall nicely
-Float height set to factory and confirmed level at gasket level with tube method
-New fuel filter
-Rebuilt petcock, and tested vacuum and fuel flow
-Pilot screw at 2.5 turns out
-Idle set to 1300s

Testing so far-
-Fuel flow from both carb drains equal and strong flow
-Fresh gas
-Fresh gas with Tectron
-Carb spray for vac leaks – none that I can find
-Cleaned Blacks carb again, same process, but swapped old factory pilot screw o ring and fuel/vent rail o rings – no change
-Black - Swapped spark plug to NGK- 7669/CR8HIX – no change
-Black - Swapped back to old HT lead wire – no change
-Black removed shims from needles – no change, ran worse, put .60mm back in
-Black – warmed bike in driveway for 10-15min (I know) tried riding the day was in the 40s – 12 miles, I could not take the choke off or the bike would not rev high enough for shifts, terrible ride, no power, temperature gauge never came up to summer operating temp.
-Black – tried last year’s air filter, not clean or touched from last season, no change

Observations
-Crazy that both bikes have the same rev wall problem.
-Both bikes ran awesome last summer, first year with bikes, never had them in cold weather before
-If I cover one air filter hole with my hand the bike revs past the wall
-Roll on throttle slowly I get to 5-6k and I can hold it for a second then drops to 3-4k and holds, any more throttle it dies, jump off throttle returns to smooth idle
-Temp 30s, 40s, 50s, no change
-Headers and tail pipe temps match on both sides
I’m really upset about this, I worked so hard this winter restoring them to factory fresh and beyond and I can get past this issue, worst part is I’ve taken down the GFs bike, so added home life pressures, Haha

Any insight would help.

March 28th, 2023, 07:08 AM	#1
Shafer ninjette.org member Name: Jay Location: Nh Join Date: Aug 2022 Motorcycle(s): 07 Ninja ex250 blue and 07 Ninja black Posts: 133	Both my baby 07’s are sick – Hitting a 4-6k rev wall Both my baby 07’s are sick – Hitting a 4-6k rev wall Winter work: 07 Black and 07 Blue *stock exhaust -New Plugs -NGK 2086 CR8HSA -Renewed HT leads – new wire cleaned connections -Cleaned air filter and proper oil with Belray – Uni NU-2366 -Valve adjustment -New oil – K&N401 / T6 10w-40 -Cleaned and split carbs, dip, ultrasonic, carb spray, compressed air, copper wire – so clean! -Replaced carb o rings with a kit -Replaced vacuum hoses with snap clips – Tygon hose used -Needle shim - .60mm -No rips in diagrams, slides move and fall nicely -Float height set to factory and confirmed level at gasket level with tube method -New fuel filter -Rebuilt petcock, and tested vacuum and fuel flow -Pilot screw at 2.5 turns out -Idle set to 1300s Testing so far- -Fuel flow from both carb drains equal and strong flow -Fresh gas -Fresh gas with Tectron -Carb spray for vac leaks – none that I can find -Cleaned Blacks carb again, same process, but swapped old factory pilot screw o ring and fuel/vent rail o rings – no change -Black - Swapped spark plug to NGK- 7669/CR8HIX – no change -Black - Swapped back to old HT lead wire – no change -Black removed shims from needles – no change, ran worse, put .60mm back in -Black – warmed bike in driveway for 10-15min (I know) tried riding the day was in the 40s – 12 miles, I could not take the choke off or the bike would not rev high enough for shifts, terrible ride, no power, temperature gauge never came up to summer operating temp. -Black – tried last year’s air filter, not clean or touched from last season, no change Observations -Crazy that both bikes have the same rev wall problem. -Both bikes ran awesome last summer, first year with bikes, never had them in cold weather before -If I cover one air filter hole with my hand the bike revs past the wall -Roll on throttle slowly I get to 5-6k and I can hold it for a second then drops to 3-4k and holds, any more throttle it dies, jump off throttle returns to smooth idle -Temp 30s, 40s, 50s, no change -Headers and tail pipe temps match on both sides I’m really upset about this, I worked so hard this winter restoring them to factory fresh and beyond and I can get past this issue, worst part is I’ve taken down the GFs bike, so added home life pressures, Haha Any insight would help.