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Discussion Starter #1
Since there are many fellow 650 riders interested in moding their OEM exhaust/air system, I thought it would be more than appropriate to post some info regarding plugging the PAIR valve.

I read many posts on many forums and I ordered the following plugs:

McMaster-Carr Number: 92805K23

PUSH-ON HIGH-TEMPERATURE SILICONE RUBBER CAP, FITS 5/8" OUTSIDE DIAMETER, 1-1/2" INSIDE HEIGHT

Cost is $ 2.35 for a package of five.
Got them within 3 business days via UPS (yes, shipping was extra but worth it).

Pictures below.
Hope this helps.:agree:

Ride Safe!
KawaKlaus
 

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I got the same ones and feel they are too big. Let me know if you have the same problem, I think the 1/2 inch ones would of been a better fit.

I still used them just had to make some adjustments.
 

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I used these which can be found at any auto parts store in the US. They are 5/8" also, but seem to fit ok. They go on with about the same pressure that the hose goes on, and then they stay. I got the impression that 1/2" would be hard to press on unless the caps are very elastic.

If the 5/8" caps didn't go on, a couple wraps around the nipple with electrical tape would fix that up.
 

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Discussion Starter #5
I got the same ones and feel they are too big. Let me know if you have the same problem, I think the 1/2 inch ones would of been a better fit.

I still used them just had to make some adjustments.
Nice. What kind of adjustment did you have to make? I spoke to the Ninja650 shop folks and they suggested that if they are too long we can cut the length to fit.
Or do you mean that the diameter (5/8) is too big?
Ride Safe.
KawaKlaus
 

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Discussion Starter #6

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Discussion Starter #7
I used these which can be found at any auto parts store in the US. They are 5/8" also, but seem to fit ok. They go on with about the same pressure that the hose goes on, and then they stay. I got the impression that 1/2" would be hard to press on unless the caps are very elastic.

If the 5/8" caps didn't go on, a couple wraps around the nipple with electrical tape would fix that up.
Great input here. Thanks for the tip with the electrical tape.
But you are saying that the 5/8 plugs you used fit just right.
Anything else to keep an eye out for with this mod?

Ride Safe!
KawaKlaus
 

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I used Elmer's stick glue caps (orange as well lol) and sealed them with a plastic high temp sealant... just another option
 

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Great input here. Thanks for the tip with the electrical tape.
But you are saying that the 5/8 plugs you used fit just right.
Anything else to keep an eye out for with this mod?

Ride Safe!
KawaKlaus
Ha... just watch out for those damn throttle bodies. I dropped a screw down it and managed to get it back out (lucky as hell), then proceeded to plug them with paper towels afterward only forgetting to take them out when i put it all back together. In the end the paper towels got sucked through and shot out of my exhaust (even luckier). I've learned my lesson haha...
 

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Great input here. Thanks for the tip with the electrical tape.
But you are saying that the 5/8 plugs you used fit just right.
Anything else to keep an eye out for with this mod?
Yes, don't forget to remove whatever you use to cover up the intakes before putting everything back together. I used tape and did just that. Sounded kinda funny when I started it and I killed it right away. My heart sank when I realized I left it in there. I thought I might have damaged the engine. Opened it all back up and the tape stuck to the side of the intakes. So maybe it's a good idea to use tape just in case you forget.
 

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Discussion Starter #11
Hey Zaph,
Thank you for posting the pic and the tape suggestion is another good one.
I will post pics when I do the mod in a few weeks...stay tuned. ;)
Ride Ssfe!

KawaKlaus
 

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I used a single marble. Tight fit, easy install, no need to remove the air box, and completely invisible.:bud:
 
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