So this service costs approximately $350 at my shop and since this was my first chance to do them, I took advantage to save some money and learn more bike maintenance. You can find full instructions in the FZ09 Service manual which you can find and download as a PDF from the vastness that is the internet.
You will need the following:
a. Spark plug socket or really long regular socket. Spark plugs seem to be a pretty standard size so check your sockets against your new plugs to determine which size socket you need.
b. Ball End Hex Key 5mm and 4mm
c. Pliers to get at the hose clamps
d. a soft spot to put the Gas tank
e. A rag to wrap around the end of the fuel hose.
f. Socket Extensions
g. Universal Elbow
h. Ratchet
i. Vacuum hose (3/8in or 9.5mm)
--Edited 8/17/17 for Pics--
What you need:
1. Remove the fake air scoops. (2 push pins, 1 hex bolt [each side]) Give it a firm pull to remove.
2. Remove the plastic tank cover up by the front of the tank (4 push pins)
3. Remove the tank (4 hex bolts)
3a. Lift tank slightly to unplug breather hose, unplug overflow hose, unclip fuel pump wiring harness, Unplug fuel line (slide orange clip down, press both blue buttons on the sides to remove. there is a valve to keep the fuel from coming out of the tank so dont worry about leaks.) wrap rag around the end of the fuel hose to catch the drips
4. Unbolt Airbox, unplug ECU wire harness and move it aside (3 hex bolts)
4a. Unclip vacuum hoses (2x) from bottom of airbox
4a. You will need to loosen the three hose clamps on the intake runners, these are captive and will not be lost into the depths of the bike. It was helpful to use a hex key with a ball end to get at the hose clamps from odd angles. Loosen and lift/remove airbox.
5. Remove AIS system by sliding it off the mount on the fan shroud, and loosening hose clips to the engine. Unclip blue connector to wire harness.
6. Unclip wiring harness from coil packs (3x)
7. Remove coil packs by hand. (They're stuck in there nice and snug, just keep working it back and forth. Might help to find someone w small hands since tools may damage the plastic coil packs.
8. Using extensions and elbows remove spark plugs. I also used a piece of vacuum hose to remove the plugs since they tend to stay in there when you remove the socket.
9. Gap new plugs to .8mm or .9mm and install by hand using the same vacuum hose. Although the manual specifies 9.4 ft lbs for torque spec. Using an elbow and extensions caused me to have little faith in my torque wrench. I just attached the ratchet and turned 1/8 turn to tighten. Do not over tighten or you will have costly problems.
10. Reinstall the coil packs ensuring they are fully seated to the motor. The rubber ring on the outside of the coil pack should be nicely sealed against the valve cover to prevent dust from getting in. Plug in coil packs to the wiring harness.
11. Reinstall AIS
12. Reinstall Airbox
13. Reinstall Tank, before you bolt it all down, turn the bike on and let it run for a couple seconds to test your work.
14. Reinstall Tank covers and fake air scoops.
15. Follow me on Instagram @cjymiller
16. You win, crack a beer
You will need the following:
a. Spark plug socket or really long regular socket. Spark plugs seem to be a pretty standard size so check your sockets against your new plugs to determine which size socket you need.
b. Ball End Hex Key 5mm and 4mm
c. Pliers to get at the hose clamps
d. a soft spot to put the Gas tank
e. A rag to wrap around the end of the fuel hose.
f. Socket Extensions
g. Universal Elbow
h. Ratchet
i. Vacuum hose (3/8in or 9.5mm)
--Edited 8/17/17 for Pics--
What you need:




1. Remove the fake air scoops. (2 push pins, 1 hex bolt [each side]) Give it a firm pull to remove.


2. Remove the plastic tank cover up by the front of the tank (4 push pins)


3. Remove the tank (4 hex bolts)


3a. Lift tank slightly to unplug breather hose, unplug overflow hose, unclip fuel pump wiring harness, Unplug fuel line (slide orange clip down, press both blue buttons on the sides to remove. there is a valve to keep the fuel from coming out of the tank so dont worry about leaks.) wrap rag around the end of the fuel hose to catch the drips


4. Unbolt Airbox, unplug ECU wire harness and move it aside (3 hex bolts)


4a. Unclip vacuum hoses (2x) from bottom of airbox


4a. You will need to loosen the three hose clamps on the intake runners, these are captive and will not be lost into the depths of the bike. It was helpful to use a hex key with a ball end to get at the hose clamps from odd angles. Loosen and lift/remove airbox.

5. Remove AIS system by sliding it off the mount on the fan shroud, and loosening hose clips to the engine. Unclip blue connector to wire harness.

6. Unclip wiring harness from coil packs (3x)

7. Remove coil packs by hand. (They're stuck in there nice and snug, just keep working it back and forth. Might help to find someone w small hands since tools may damage the plastic coil packs.

8. Using extensions and elbows remove spark plugs. I also used a piece of vacuum hose to remove the plugs since they tend to stay in there when you remove the socket.


9. Gap new plugs to .8mm or .9mm and install by hand using the same vacuum hose. Although the manual specifies 9.4 ft lbs for torque spec. Using an elbow and extensions caused me to have little faith in my torque wrench. I just attached the ratchet and turned 1/8 turn to tighten. Do not over tighten or you will have costly problems.
10. Reinstall the coil packs ensuring they are fully seated to the motor. The rubber ring on the outside of the coil pack should be nicely sealed against the valve cover to prevent dust from getting in. Plug in coil packs to the wiring harness.
11. Reinstall AIS
12. Reinstall Airbox
13. Reinstall Tank, before you bolt it all down, turn the bike on and let it run for a couple seconds to test your work.
14. Reinstall Tank covers and fake air scoops.
15. Follow me on Instagram @cjymiller
16. You win, crack a beer