Ninja 250 & 300 Valve Spring Thread

garth285 · April 4th, 2015, 02:33 PM

Hey guys, I have been gathering information about the top end of the 08-12 ninja 250 which also has most of the same valvetrain as the ninja 300 as well.

Anyways I'm a bit short on time right now but I did find out that the stock valve springs have VERY little pressure at rest which this may be the cause of my turbo problems.

Well this thread I'll post all the valve spring tech info I gather and will share with whoever may need it!

Stock Valve Spring
39.29mm (1.547") free length
35.64mm (1.403") Valve Spring installed height

24lbs of spring pressure at installed height

104lbs of spring pressure at .302" lift - 1.103" spring length

100% coil bind is at 26.6mm

at 1/2" compression it has 116lbs of pressure
1/8" compression it has 46lbs

Spring OD - 20.9mm - 0.819"
Spring ID - 14.5mm - .568"
Spring Coil - 3.3mm - .130"

Will post more info when I have the time!!!

garth285 · April 5th, 2015, 07:15 AM

Some more information:

Stock Camshaft measurements
Intake - Exhaust
Cam Base 1.024 - 1.031
Cam Peak 1.332 - 1.297
Lift in in .308" - .266"
Lash Specs .006-.009 - .009-.011:
Intake actual lift with .006" - .302"
Exhaust actual lift with .009" - .257"

Installed height - 1.405" or 35.687mm - 24lbs of seat pressure
intake lift of .305" = spring length of 1.103" = 104lbs of seat pressure

garth285 · April 5th, 2015, 08:27 AM

Some more measurements:

Coil Bind:
.050" clearance = 30.1mm
.030" clearance = 27.9mm
.020" clearance = 27.1mm

With that if I went to a 1mm (.040") shim it would make my resting spring pressure 34lbs up from 24lbs and 114lbs at full lift

Now I just have to wait for some other springs to come in to test and we'll see what they run at. I'd prefer not to shim mine but we'll see!

garth285 · April 7th, 2015, 06:05 AM

08+ 250 and 300 valve spring retainer specs:

garth285 · April 7th, 2015, 06:07 AM

Valve Spring Seat Dimensions:
OD - 22.58mm
ID - 9.38mm
Thickness - 1.04mm (.041")

Top of valve stem to valve stem seal:
18.9mm

Tappet specs:
OD - 24.0mm
ID - 22.78mm
Height - 17.02mm

swarfman64 · April 7th, 2015, 06:34 AM

interesting....

garth285 · April 7th, 2015, 06:45 AM

Quote:

Originally Posted by swarfman64

interesting....

VERY! I dont know why they have such low spring pressure at installed height but I plan on fixing that.

The only thing that is going to change with all this data is I ordered a brand new spring to test, I have been testing a spring out of a non boosted motor so we'll see if brand new they have better pressure.

Waiting for parts to come in

garth285 · April 7th, 2015, 07:29 AM

Stock and aftermarket Cam specs:

Swann · April 7th, 2015, 03:36 PM

Thanks Garth,

this is useful information.

garth285 · April 9th, 2015, 02:47 PM

today I got in some new valve springs, I ordered a stock 250 and 300 valve spring (They changed part numbers in 2010) and the both have just about the same spring pressure, the 250's read 18lbs and the 300's read 20lbs but my digital spring tester only reads in 2lbs increments so it can be very close, shimmed down .040" they both showed 28lbs and they both had 96lbs at full lift.

I am waiting for some other springs to come in to test out, I did find one company that has the right OD and ID springs for the 250's but they are slightly shorter and would need to be shimmed which would be easy since the stock valve seats are .040" but they have about 37lbs on them

one of the springs I tested has an inner and an outer spring, I only got the inner in and waiting on the outer but if I could somehow get a dual spring setup that would work as well but I dont think thats going to fly since the retainers dont look like they will work out with the different valve stems.... sigh.... I tested this inner spring and it had 22lbs of pressure at the 250 installed height, running that inner and a stock 250 spring it got me 38lbs at installed height and 160 at full lift. Thats where I'd like to be but the inner spring doesnt fit inside. I am hoping the outter spring is stronger than the 250 and isnt to wide but I'll have to wait until these springs come in.

Will keep you guys updated

cuong-nutz · April 9th, 2015, 03:55 PM

Drunk post. Did not see earlier postsssss

garth285 · April 9th, 2015, 04:06 PM

Quote:

Originally Posted by cuong-nutz

Drunk post. Did not see earlier postsssss

Lol sounds good!

garth285 · April 10th, 2015, 10:59 AM

Some kawasaki springs I measured that will not work :-( Figured I'd post these incase someone needed them some day

Part # 49078-1146
OD - 21.48mm
ID - 14.58mm
Length - 46.4mm

Part # 49078-1127
OD - 17.15mm
ID - 11.8mm
Length - 40.98mm

garth285 · April 18th, 2015, 03:06 PM

I think I found a spring!!!!!!!

Kawasaki Part number 49078-1216
Fits:
ZX600-K1 (Ninja ZX-6RR) (2003)
ZX636-B1 (Ninja ZX-6R) (2003)
ZX636-B2 (Ninja ZX-6R) (2004)
ZX636-C1 (Ninja ZX-6R) (2005)
ZX636C6F (Ninja ZX-6R) (2006)
ZX636D6F (Ninja ZX-6R) (2006)

Below is a spreadsheet I made of the springs I have tested. It includes an OD, ID, Free Length, Installed Height Pressure (35.76mm), and a Full Lift pressure (28.02mm)

I also ordered extra spring seats which measure out at .0415" or about 1.03mm With those I shimmed up the spring that was working out the best which was the ZX636 spring. With no shims it read 24lbs, 1 was 36lbs and 2 was 48lbs

So now I have to decide if I want to run 1 or 2 shims on this spring to have either 36 or 48lbs of spring pressure!

I really hope this will help with my turbo bike IF I am experiencing valve float.

garth285 · April 20th, 2015, 07:40 AM

OK lets try this one last time!

Last night I decided to go out to the garage and just double check my measurements, this time I used a digital SAE caliper and I was able to make sure my readings were spot on, I verfied accuracy with a standard caliper. My measruements were just about spot on but were .003" off which isnt anything to really sneeze at if you think about it but I figured I would re measure all the springs again and list them with the installed height and the max lift assuming that there was .006" lash on the intake and .009" on the exhaust.

So the FINAL installed height measurement was 1.405" and the full lift with a intake cam is 1.103" On the note of the cams I also measure out the cams before using MM and converted it well this time I took my measurements direct in Inch so the full lift of the intake cam was .308" and exhaust was .266" (these are not new cams, used with 8-10k miles)

It still looks like the 636 spring will be working the best to get the most amount of spring pressure while keeping a .020" clearance between the coils it has a 46# seat pressure at installed height and 154# at full lift That is with the spring and 2 extra shims (.080"). The next runner up would be the kx250 spring which with 3 shims has 36# of seat pressure but only 100# at full lift, this might help keep the power up depending on how hard it is for this little engine to lift the valves open. A happy medium would be the 636 spring with 1 shim and it would give me 34# and 134#

Anyways below is a spreadsheet of the springs I have tested along with their dimensions and the number of shims used. and below that is a updated chart of cam specs.

One last thing I found out the 03 636/600 which is the 1216 spring also had a race exhaust valve spring you can order from the factory, I dont think I can get my hands on them since they made them oh 11 years ago but I'm going to try and test one of those!

Will keep all posted!

swarfman64 · April 21st, 2015, 05:14 AM

Wow! you have been busy. Nice work

garth285 · April 21st, 2015, 06:17 AM

Quote:

Originally Posted by swarfman64

Wow! you have been busy. Nice work

Thanks! I am hoping this will pay off!

The last spring I want to try out is a race kit spring out of a 636. I am going to order it and see if its any better.

garth285 · April 25th, 2015, 04:41 PM

OK..... So I tested one last spring it is a race exhaust spring for the 03-06 ZX-6rr. This spring has the following measurements:

Part Number - 49078-0006
O.D. - .8235"
I.D. - .5540"
Length - 1.6470"

at the 250s installed height of 1.405" below is the spring pressure with the amount of shims:
0 - 26
1 - 32
2 - 42

At full lift minus .006" for lash (1.103") here is the spring pressures:
0 - 114
1 - 128
2 - 142

I could not get a .020" feeler gauge in with 2 shims though with this spring. The most I'd run this would be with 1 shim which would give me 32 and 128 pounds of spring pressure and clear from coil bind.

I am going to run the 03-06 636 exhaust valve spring on the intake and exhaust of my 250 motor. Going to shim the intake side with 2 shims and the exhaust with 1 shim so 46lbs on the intake side and 34 on the exhaust. Going to order a set of brand new springs and give it a go! Hopefully will have the head back together sometime by the end of next week and then swap motors over and give it a go!

If anyone needs a little more valve spring for their 250-300 I'd suggest running the 03-06 636 spring with 1 extra spring seat

636 spring - 49078-1216
250/300 spring seat - 16007-0028

garth285 · April 29th, 2015, 01:40 PM

Good news, found another spring that will work and may be better than the 636 the 09-12 exhaust valve springwith 2 shims I can get 46# at installed height and at full lift 142# but the big difference between the two is I have a bit more of clearance for coil bind a little over .010"

with 1 shim it will give me 34# and 128#

I have one last spring which is a exhaust spring from a 13-15 zx6r to test out and then will see which one is the best.

Kawasaki Part number 49078-0076
O.D - .884"
ID - .556
Length - 1.579"

garth285 · May 1st, 2015, 01:15 PM

More and more progress!

below is a chart of spring with the 09-12 and the 13-15 zx6r spring spec's I have ordered 7 more springs to make a set of 8 but I am going to go with the 13-15 zx6r spring.

The numbers below the spring rates at full lift is clearance to coil bind. Will most more info later:

micoulisninja · May 26th, 2015, 01:21 PM

@garth286
i have found a set of '09-'12 ZX-6r exhaust springs on ebay... but they say part number is 49078-0075... you think they are different to the 0076 ones you have tested ? can we get any data on those ?

garth285 · May 26th, 2015, 01:23 PM

Quote:

Originally Posted by micoulisninja

@garth286
i have found a set of '09-'12 ZX-6r exhaust springs on ebay... but they say part number is 49078-0075... you think they are different to the 0076 ones you have tested ? can we get any data on those ?

the 0075's were replaced by the 0076. I only tested the 76's but I am willing to bet the 75s are the same!

garth285 · May 26th, 2015, 04:22 PM

Hey guess what, it was the 0075's I tested! I'll PM ya!

redkid · October 12th, 2016, 04:22 PM

Sorry for waking up this old thread, but what was the results of the 636 springs?

garth285 · October 13th, 2016, 10:58 AM

Quote:

Originally Posted by redkid

Sorry for waking up this old thread, but what was the results of the 636 springs?

which year 636?

redkid · October 13th, 2016, 04:23 PM

The 13-15 636. So which springs did you ended up with?

garth285 · October 13th, 2016, 06:20 PM

Quote:

Originally Posted by redkid

The 13-15 636. So which springs did you ended up with?

yes I wound up running those springs and actually shimmed them for more pressure. They seemed to work great but after I scrapped the project I put the head back to stock and am parting out the motor.

If your interested I have a full set of the 636 springs along with a bunch of shims, let me know if you need them.

Swann · October 13th, 2016, 11:38 PM

Whats the difference with the 2016 spring?

The part number is SPRING-ENGINE VALVE,EXHAUST
49078-0718.

garth285 · October 14th, 2016, 06:32 AM

Quote:

Originally Posted by Swann

Whats the difference with the 2016 spring?

The part number is SPRING-ENGINE VALVE,EXHAUST
49078-0718.

Not sure if you saw the chart I posted, some internet connections block it like my work laptop but that part number fits the following:

Model (13): [Add Note: Model]
ZX636EDF (Ninja ZX-6R (European)) (2013)
ZX636EDF (Ninja ZX-6R) (2013)
ZX636EEF (Ninja ZX-6R) (2014)
ZX636EFF (Ninja ZX-6R) (2015)
ZX636EFFA (Ninja ZX-6R 30th Anniversary Edition) (2015)
ZX636EGF (Ninja ZX-6R) (2016)
ZX636EGFA (Ninja ZX-6R KRT Edition) (2016)
ZX636FDF (Ninja ZX-6R ABS) (2013)
ZX636FEF (Ninja ZX-6R ABS) (2014)
ZX636FFF (Ninja ZX-6R ABS) (2015)
ZX636FFFA (Ninja ZX-6R ABS 30th Anniversary Edition) (2015)
ZX636FGF (Ninja ZX-6R ABS) (2016)
ZX636FGFA (Ninja ZX-6R ABS KRT Edition) (2016)

Here is the chart of the part numbers below

JohnnyBravo · October 15th, 2016, 10:31 PM

Sad to see this project scraped but that the way things go

AG2011 · February 19th, 2017, 02:42 AM

Hello Garth285,

Sorry to wake up the threat again. I am just a new member of this community. As I just register to the board because I am really interesting to your post. So, I would to get in touch with your information more about upgrade the valve springs for 2011 Ninja250R. If you were use the valve spring 2013-2015 ZX6R, what tappets you can use with those springs.
I just have the set of 13-15 ZX6R springs (49078-0718) but they could not fit to my tappets.

Many thanks.

April 4th, 2015, 02:33 PM	#1
garth285 KAWASAKI GURU Name: Shawn Location: Florida Join Date: Jul 2013 Motorcycle(s): Turbo Ninja 250 Posts: 863	Ninja 250 & 300 Valve Spring Thread Hey guys, I have been gathering information about the top end of the 08-12 ninja 250 which also has most of the same valvetrain as the ninja 300 as well. Anyways I'm a bit short on time right now but I did find out that the stock valve springs have VERY little pressure at rest which this may be the cause of my turbo problems. Well this thread I'll post all the valve spring tech info I gather and will share with whoever may need it! Stock Valve Spring 39.29mm (1.547") free length 35.64mm (1.403") Valve Spring installed height 24lbs of spring pressure at installed height 104lbs of spring pressure at .302" lift - 1.103" spring length 100% coil bind is at 26.6mm at 1/2" compression it has 116lbs of pressure 1/8" compression it has 46lbs Spring OD - 20.9mm - 0.819" Spring ID - 14.5mm - .568" Spring Coil - 3.3mm - .130" Will post more info when I have the time!!! Last futzed with by garth285; April 20th, 2015 at 07:53 AM.
	1 out of 1 members found this post helpful.

April 5th, 2015, 07:15 AM	#2
garth285 KAWASAKI GURU Name: Shawn Location: Florida Join Date: Jul 2013 Motorcycle(s): Turbo Ninja 250 Posts: 863	Some more information: Stock Camshaft measurements Intake - Exhaust Cam Base 1.024 - 1.031 Cam Peak 1.332 - 1.297 Lift in in .308" - .266" Lash Specs .006-.009 - .009-.011: Intake actual lift with .006" - .302" Exhaust actual lift with .009" - .257" Installed height - 1.405" or 35.687mm - 24lbs of seat pressure intake lift of .305" = spring length of 1.103" = 104lbs of seat pressure Last futzed with by garth285; April 20th, 2015 at 07:55 AM.

April 5th, 2015, 08:27 AM	#3
garth285 KAWASAKI GURU Name: Shawn Location: Florida Join Date: Jul 2013 Motorcycle(s): Turbo Ninja 250 Posts: 863	Some more measurements: Coil Bind: .050" clearance = 30.1mm .030" clearance = 27.9mm .020" clearance = 27.1mm With that if I went to a 1mm (.040") shim it would make my resting spring pressure 34lbs up from 24lbs and 114lbs at full lift Now I just have to wait for some other springs to come in to test and we'll see what they run at. I'd prefer not to shim mine but we'll see! Last futzed with by garth285; April 20th, 2015 at 07:56 AM.

April 7th, 2015, 06:34 AM	#6
swarfman64 Master modder Name: Andrew Location: Australia Join Date: Jan 2014 Motorcycle(s): TURBO gpx250 99 CB250/500rs Sherco290 Trials Indian 1911big base (replica) Posts: 138	interesting.... __________________________________________________ [B]Come and see my turbo ninja build, dyno build and other stuff at http://swarfman64.blogspot.com.au/20...rtia-dyno.html

April 9th, 2015, 03:55 PM	#11
cuong-nutz RIP Alex Name: Cuong Location: Houston, TX Join Date: Apr 2011 Motorcycle(s): '10 250r, '09 265r Posts: A lot. Blog Entries: 2	Drunk post. Did not see earlier postsssss __________________________________________________ HalfFast Racing Team Serving Greater Houston Area Riders:WFO Riders MotoHouston HPC CMRA Ride Smart Fastline Lone Star Track Days
	1 out of 1 members found this post helpful.

April 7th, 2015, 06:07 AM	#5
garth285 KAWASAKI GURU Name: Shawn Location: Florida Join Date: Jul 2013 Motorcycle(s): Turbo Ninja 250 Posts: 863	Valve Spring Seat Dimensions: OD - 22.58mm ID - 9.38mm Thickness - 1.04mm (.041") Top of valve stem to valve stem seal: 18.9mm Tappet specs: OD - 24.0mm ID - 22.78mm Height - 17.02mm

April 7th, 2015, 03:36 PM	#9
Swann ninjette.org member Name: Jake Location: Manila Join Date: Apr 2014 Motorcycle(s): 250R Posts: 135	Thanks Garth, this is useful information.

April 9th, 2015, 02:47 PM	#10
garth285 KAWASAKI GURU Name: Shawn Location: Florida Join Date: Jul 2013 Motorcycle(s): Turbo Ninja 250 Posts: 863	today I got in some new valve springs, I ordered a stock 250 and 300 valve spring (They changed part numbers in 2010) and the both have just about the same spring pressure, the 250's read 18lbs and the 300's read 20lbs but my digital spring tester only reads in 2lbs increments so it can be very close, shimmed down .040" they both showed 28lbs and they both had 96lbs at full lift. I am waiting for some other springs to come in to test out, I did find one company that has the right OD and ID springs for the 250's but they are slightly shorter and would need to be shimmed which would be easy since the stock valve seats are .040" but they have about 37lbs on them one of the springs I tested has an inner and an outer spring, I only got the inner in and waiting on the outer but if I could somehow get a dual spring setup that would work as well but I dont think thats going to fly since the retainers dont look like they will work out with the different valve stems.... sigh.... I tested this inner spring and it had 22lbs of pressure at the 250 installed height, running that inner and a stock 250 spring it got me 38lbs at installed height and 160 at full lift. Thats where I'd like to be but the inner spring doesnt fit inside. I am hoping the outter spring is stronger than the 250 and isnt to wide but I'll have to wait until these springs come in. Will keep you guys updated

April 10th, 2015, 10:59 AM	#13
garth285 KAWASAKI GURU Name: Shawn Location: Florida Join Date: Jul 2013 Motorcycle(s): Turbo Ninja 250 Posts: 863	Some kawasaki springs I measured that will not work :-( Figured I'd post these incase someone needed them some day Part # 49078-1146 OD - 21.48mm ID - 14.58mm Length - 46.4mm Part # 49078-1127 OD - 17.15mm ID - 11.8mm Length - 40.98mm

April 21st, 2015, 05:14 AM	#16
swarfman64 Master modder Name: Andrew Location: Australia Join Date: Jan 2014 Motorcycle(s): TURBO gpx250 99 CB250/500rs Sherco290 Trials Indian 1911big base (replica) Posts: 138	Wow! you have been busy. Nice work __________________________________________________ [B]Come and see my turbo ninja build, dyno build and other stuff at http://swarfman64.blogspot.com.au/20...rtia-dyno.html

April 25th, 2015, 04:41 PM	#18
garth285 KAWASAKI GURU Name: Shawn Location: Florida Join Date: Jul 2013 Motorcycle(s): Turbo Ninja 250 Posts: 863	OK..... So I tested one last spring it is a race exhaust spring for the 03-06 ZX-6rr. This spring has the following measurements: Part Number - 49078-0006 O.D. - .8235" I.D. - .5540" Length - 1.6470" at the 250s installed height of 1.405" below is the spring pressure with the amount of shims: 0 - 26 1 - 32 2 - 42 At full lift minus .006" for lash (1.103") here is the spring pressures: 0 - 114 1 - 128 2 - 142 I could not get a .020" feeler gauge in with 2 shims though with this spring. The most I'd run this would be with 1 shim which would give me 32 and 128 pounds of spring pressure and clear from coil bind. I am going to run the 03-06 636 exhaust valve spring on the intake and exhaust of my 250 motor. Going to shim the intake side with 2 shims and the exhaust with 1 shim so 46lbs on the intake side and 34 on the exhaust. Going to order a set of brand new springs and give it a go! Hopefully will have the head back together sometime by the end of next week and then swap motors over and give it a go! If anyone needs a little more valve spring for their 250-300 I'd suggest running the 03-06 636 spring with 1 extra spring seat 636 spring - 49078-1216 250/300 spring seat - 16007-0028

April 29th, 2015, 01:40 PM	#19
garth285 KAWASAKI GURU Name: Shawn Location: Florida Join Date: Jul 2013 Motorcycle(s): Turbo Ninja 250 Posts: 863	Good news, found another spring that will work and may be better than the 636 the 09-12 exhaust valve springwith 2 shims I can get 46# at installed height and at full lift 142# but the big difference between the two is I have a bit more of clearance for coil bind a little over .010" with 1 shim it will give me 34# and 128# I have one last spring which is a exhaust spring from a 13-15 zx6r to test out and then will see which one is the best. Kawasaki Part number 49078-0076 O.D - .884" ID - .556 Length - 1.579" Last futzed with by garth285; April 30th, 2015 at 06:18 AM.

May 1st, 2015, 01:15 PM	#20
garth285 KAWASAKI GURU Name: Shawn Location: Florida Join Date: Jul 2013 Motorcycle(s): Turbo Ninja 250 Posts: 863	More and more progress! below is a chart of spring with the 09-12 and the 13-15 zx6r spring spec's I have ordered 7 more springs to make a set of 8 but I am going to go with the 13-15 zx6r spring. The numbers below the spring rates at full lift is clearance to coil bind. Will most more info later:

May 26th, 2015, 01:21 PM	#21
micoulisninja modaholic junkie Name: Nick Location: Athens, Greece Join Date: Sep 2012 Motorcycle(s): 2001 ZX-12R, 2009 ninja 345cc and plenty of others in the past... Posts: 438 Blog Entries: 2	@garth286 i have found a set of '09-'12 ZX-6r exhaust springs on ebay... but they say part number is 49078-0075... you think they are different to the 0076 ones you have tested ? can we get any data on those ? __________________________________________________ If noone has tried it before, I will !!!

May 26th, 2015, 04:22 PM	#23
garth285 KAWASAKI GURU Name: Shawn Location: Florida Join Date: Jul 2013 Motorcycle(s): Turbo Ninja 250 Posts: 863	Hey guess what, it was the 0075's I tested! I'll PM ya!

October 12th, 2016, 04:22 PM	#24
redkid ninjette.org member Name: red Location: KL, Malaysia Join Date: Nov 2011 Motorcycle(s): ninja 250r Posts: 34	Sorry for waking up this old thread, but what was the results of the 636 springs?

October 13th, 2016, 04:23 PM	#26
redkid ninjette.org member Name: red Location: KL, Malaysia Join Date: Nov 2011 Motorcycle(s): ninja 250r Posts: 34	The 13-15 636. So which springs did you ended up with?

October 13th, 2016, 11:38 PM	#28
Swann ninjette.org member Name: Jake Location: Manila Join Date: Apr 2014 Motorcycle(s): 250R Posts: 135	Whats the difference with the 2016 spring? The part number is SPRING-ENGINE VALVE,EXHAUST 49078-0718.

October 15th, 2016, 10:31 PM	#30
JohnnyBravo Certifiable nontundrum Name: Harper Location: NC Milkshake stand Join Date: Mar 2013 Motorcycle(s): 2013 SE NINJA 300 Posts: Too much. MOTM - Sep '13, Sep '16	Sad to see this project scraped but that the way things go __________________________________________________

February 19th, 2017, 02:42 AM	#31
AG2011 ninjette.org newbie Name: Sombat Location: Bangkok Thailand Join Date: Feb 2017 Motorcycle(s): 2011 Ninja250R Posts: 1	Hello Garth285, Sorry to wake up the threat again. I am just a new member of this community. As I just register to the board because I am really interesting to your post. So, I would to get in touch with your information more about upgrade the valve springs for 2011 Ninja250R. If you were use the valve spring 2013-2015 ZX6R, what tappets you can use with those springs. I just have the set of 13-15 ZX6R springs (49078-0718) but they could not fit to my tappets. Many thanks.

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