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Old March 18th, 2019, 11:22 AM   #1
NiklasPhabi
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2006 Valve clearance

Hey there dear friends,

I am starting to go insane over my 2006 Ninja 250R. I re-did my valve clearings now a couple of times, but still feel like I have symptoms of too tight clearances (rough idle, stall at 5000-6000 rpms, occasional backfire).

I did the adjustment according to faq.ninja250.org (here), i.e.

Exhaust: 0.11mm - 0.16mm
Intake: 0.08mm - 0.13mm

I am however also in possession (e.g. from here) of a service manual for the 2008 Ninja 250R, which states.

Exhaust: 0.22 ∼ 0.29 mm
Intake: 0.15 ∼ 0.24 mm

I spent hours on the internet trying to find the specific ranges for the 2006, but seem to be approaching this search wrong. I would appreciate any kind o help!

Thanks a lot
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Old March 18th, 2019, 02:59 PM   #2
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there's a sticker on the inside of the side cover (I think it's the left one) with the specs.

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Old March 18th, 2019, 03:02 PM   #3
NiklasPhabi
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Thank you so much for the reply! Side cover as in fairings? Unfortunately I got my bike completely naked. No covers no fairings.
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Old March 18th, 2019, 03:11 PM   #4
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Yep, it's under the left side, under tank and seat.

DSCF0019.jpg
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Old March 18th, 2019, 03:22 PM   #5
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the newgen (2008 and on) 250s have cams on shims, (no rockers), the pregens (up to and including 2007) have adjustable rockers.
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Old March 18th, 2019, 03:25 PM   #6
NiklasPhabi
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awesome. Thank you so much. I take it this is from a Ninja 2002 (EX250-F16)? And then assume same specs are valid for my 2006.

If that is the case, my valve gaps are within specs. I guess the symptoms I have been blaming on the valves so far are actually carb related then. Off to a new adventure then!
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Old March 18th, 2019, 03:29 PM   #7
NiklasPhabi
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Wait. Ok. Now I am incredibly confused.

There seems to be something very fishy going on with my bike. The title says it is 2006. (With Frame number Range: JKAEXMF1*6DA*). But the bike DOES have cams on shims, not rockers! I get the feeling that a previous owner might have switched engines! Holy cow.
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Old March 18th, 2019, 03:52 PM   #8
NiklasPhabi
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ok. I cannot stop laughing. Suspicions confirmed. The tile states Engine number: EX250EEA21*. According to faq.ninja250.org, that probably is a 2006 or 2007 engine.

However, the number engraved on the engine is EX250JEA3* which seems to be 2009 or 2010?

Would that engine have the same clearances as the 2008 engine, i.e.

Exhaust: 0.22 ∼ 0.29 mm
Intake: 0.15 ∼ 0.24 mm
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Old March 18th, 2019, 04:58 PM   #9
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Quote:
Originally Posted by NiklasPhabi View Post
ok. I cannot stop laughing. Suspicions confirmed. The tile states Engine number: EX250EEA21*. According to faq.ninja250.org, that probably is a 2006 or 2007 engine.

However, the number engraved on the engine is EX250JEA3* which seems to be 2009 or 2010?

Would that engine have the same clearances as the 2008 engine, i.e.

Exhaust: 0.22 ∼ 0.29 mm
Intake: 0.15 ∼ 0.24 mm
Yep, would be "newgen" specs. Not an uncommon swap at all.
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Old March 18th, 2019, 05:06 PM   #10
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How interesting! I was riding the bike yesterday and it was bad, but kind of OK. I am surprised it ran at all with the clearances set way out of spec (I guess I set them to the upper limit of the oldgen, which means very lower limit of the newgen).

Cannot wait to set them right and finally have this problem done with!

Z1R rider, you are an angel! Thank you so much for figuring this out with me.
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Old March 18th, 2019, 05:44 PM   #11
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Curious.... when you bought the bike, the Previous Owner didn't advise you of the engine swap?

You're in possession of a shim kit? Did you take notes when you first checked the valves ...the clearances and placement of the size of the shim in each valve location? If so...your notes may prove to save you some time.

BTW..."shim under bucket" is the proper nomenclature for the newgen valve system. "Screw and locknut" for the older style.
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Old March 18th, 2019, 06:15 PM   #12
NiklasPhabi
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PO claimed she only had the bike for a couple of months and never got it running. She seemed a bit over her head with the bike and herself claimed that she bought it from a guy who had no idea what he was doing. ... kids! (this is my first bike, but I didn't go to engineering school for nothing ).

Yeah, I am in possession of shim kit. I also wrote the clearances down, but I might have thrown away the paper ... Luckily, I have done it three times now and I think I have a pretty efficient system down.

"Shim under Bucket" and "Screw and Locknut" sound like incredibly appropriate terms. I will remember them.

Thank you guys so much. I wish I would have come here earlier!!
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Old March 18th, 2019, 06:30 PM   #13
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Quote:
Originally Posted by ducatiman View Post
BTW..."shim under bucket" is the proper nomenclature for the newgen valve system.
Thanks, I didn't know if they were over or under as I don't have a newer one, just a stable of old ones. My old Z1R's got them on top.
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