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I would like to start off by saying this is simply a guide. I am not a certified mechanic nor do I claim to be one. In other words, *WORK AT YOUR OWN RISK*
With that out of the way, Welcome to my Ninja 650R Valve Clearance Adjustment Guide. My bike is a Passion Red 07. I know 06-08 bikes should be identical. The 09 bikes may differ in some ways. I don’t have an 09, so I don’t know. If you don’t have the tools listed below or are not mechanically inclined go ahead a turn back because this is not a task for the faint hearted. You also need a working knowledge of how the motor in our bike runs, as this guide will not explain every last bit to you. I recommend going to HowItWorks.com are reviewing four stroke engines before starting on this project. If you are unsure about doing this procedure take it to a mechanic. You may run into trouble, if parts are damaged, cam chain timing is off (not likely) etc. then you are on your own. You can send me a private message and I can help to the best of my knowledge but as I stated I am not a mechanic.
It is important to have the service manual for the bike that can be found at http://homepages.slingshot.co.nz/~shanetp/Index.html#_Manuals_&_Parts_1
If you are uncertain about anything look at the shop manual for further instruction.
Here are some rules to live by:
1. Always start off with less force then proceed to use more force, you can’t unstrip bolts, unshear bolt caps, and put marred metal back together.
2. Always plug holes that things can fall down and mark spots that tubes go with masking tape.
3. Rescrew in bolts when you can. Make sure to keep the bolts and screws with the pieces they go with otherwise you’re going to end up with extra parts when you finish and that can end up nasty.
4. In light of rule 3, try to put the bolts into the same holes they came from. Bolts tend to imprint themselves into where they are mounted and work best in the original hole they were in.
5. Be patient. If you get rushed you are more likely to screw things up. This project took me a good 8 hours (including a parts run and breaks).
6. Work parts out slowly. Never yank on things or apply large amounts of pressure.
7. Read ahead few steps before proceeding, I try to organize this the best I can but I am not perfect.
I would like to point out that I have highlighted things in the pictures. Blue means remove, Red means beware (if you drop things down these holes you will have to take the whole engine apart to get them back), Green means pay attention, Turquoise means retighten to spec. Some things will need specific tightening amounts, some can be felt. I will site the amount of ft lbs of torque when it is required. Threadlocker is good to use on stress bearing parts that are non greasy.
Your bike must be cold in order to do this project. Make sure that it has been sitting overnight.
With that out of the way, Welcome to my Ninja 650R Valve Clearance Adjustment Guide. My bike is a Passion Red 07. I know 06-08 bikes should be identical. The 09 bikes may differ in some ways. I don’t have an 09, so I don’t know. If you don’t have the tools listed below or are not mechanically inclined go ahead a turn back because this is not a task for the faint hearted. You also need a working knowledge of how the motor in our bike runs, as this guide will not explain every last bit to you. I recommend going to HowItWorks.com are reviewing four stroke engines before starting on this project. If you are unsure about doing this procedure take it to a mechanic. You may run into trouble, if parts are damaged, cam chain timing is off (not likely) etc. then you are on your own. You can send me a private message and I can help to the best of my knowledge but as I stated I am not a mechanic.
It is important to have the service manual for the bike that can be found at http://homepages.slingshot.co.nz/~shanetp/Index.html#_Manuals_&_Parts_1
If you are uncertain about anything look at the shop manual for further instruction.
Here are some rules to live by:
1. Always start off with less force then proceed to use more force, you can’t unstrip bolts, unshear bolt caps, and put marred metal back together.
2. Always plug holes that things can fall down and mark spots that tubes go with masking tape.
3. Rescrew in bolts when you can. Make sure to keep the bolts and screws with the pieces they go with otherwise you’re going to end up with extra parts when you finish and that can end up nasty.
4. In light of rule 3, try to put the bolts into the same holes they came from. Bolts tend to imprint themselves into where they are mounted and work best in the original hole they were in.
5. Be patient. If you get rushed you are more likely to screw things up. This project took me a good 8 hours (including a parts run and breaks).
6. Work parts out slowly. Never yank on things or apply large amounts of pressure.
7. Read ahead few steps before proceeding, I try to organize this the best I can but I am not perfect.
I would like to point out that I have highlighted things in the pictures. Blue means remove, Red means beware (if you drop things down these holes you will have to take the whole engine apart to get them back), Green means pay attention, Turquoise means retighten to spec. Some things will need specific tightening amounts, some can be felt. I will site the amount of ft lbs of torque when it is required. Threadlocker is good to use on stress bearing parts that are non greasy.
Your bike must be cold in order to do this project. Make sure that it has been sitting overnight.