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DIY Sparkplug Change

56K views 33 replies 20 participants last post by  PaulNYC  
#1 · (Edited)
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:
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1. Remove the fake air scoops. (2 push pins, 1 hex bolt [each side]) Give it a firm pull to remove.
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2. Remove the plastic tank cover up by the front of the tank (4 push pins)
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3. Remove the tank (4 hex bolts)
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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
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4. Unbolt Airbox, unplug ECU wire harness and move it aside (3 hex bolts)
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4a. Unclip vacuum hoses (2x) from bottom of airbox
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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.
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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.
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6. Unclip wiring harness from coil packs (3x)
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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.
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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.
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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
 
#2 ·
Thanks! Saving this for later
 
#8 ·
I did mine this past weekend and took some pictures which I'll be adding to this thread in the next week or so. Until then if you run into anything feel free to post up and I may have a picture of it. They're all on my phone at the moment waiting to be copied off.
 
#12 · (Edited)
need a youtube video doing this.........

I can't believe how much is involved just to change the spark plug,

wish you didnt have to remove the gas tank, what a pain,

I have a feeling the spark plugs in the motor now, will be with the bike forever.....haha.
 
#11 ·
beware when you take your vehicle to a shop and they say "yea we dont do anything for free"

they will give you a quote on labor rate/hour, then say "whenever I get done"

haha. stay away from places like that....
 
#10 · (Edited)
FYI - If you get block-off plates for the AIS and do them when you change your plugs it makes it easier in the future to get to the plugs. It also cleans up the area nicely and you do not have to mess with those damn hoses anymore. The block-off plates are cheap and makes maintenance easier under the air box. Its a win win.
 
#15 · (Edited)
I just changed the stock plugs at 10,500 miles. The stock plugs still looked good. I also used NGK, CR9EIX 3521 (Iridium no gap needed). I"m glad that I put block off plates in when I put my header on (over a year ago), it made the job a lot easier not having to work around all that AIS garbage. The bike idles a lot smoother now. Any one needing a video can go to sport bike track gear, for a how to video on installing block off plates. The plugs are right next to them, set into the motor. For me getting the plug caps off was the hardest part. I used a channel lock pliers with a rag over them so that i didn't scar the plug caps. I read that someone else used this method on this site and it worked good for me also. Be sure to also check your clutch cable as it runs against the frame at the radiator. My cable had a wear mark thru the cable protective sleeve. I added a piece of heat shrink on that scared area. Also put a small dab of grease at the cable end where it goes into the leaver.
 
#16 ·
Is it just me, or does anyone else find out odd to change plus so early, i understand being pre-emptive, but the plus are designed to lay much longer despite what the manual says. I hope people realize that allot of that maintenance schedule is to get you to the dealership. There should be nothing wrong with a plug that only has 8k. I've gone much longer on other bikes. Don't plan on changing these till i hit 20k.

Sent from my N9810 using Tapatalk
 
#33 ·
no the manual says 12k. Idk though on my old ZX6R it called for plugs at 7500mi. I ran the OEM plugs until 13k and then had issues starting it.
 
#17 ·
It would be interesting to hear from members that replaced their plugs at 8,000 miles. Kevinh already said his plugs were still good at 10,000 mi.
cjymiller, Camp, electricblue... do you guys feel you could have gone longer on those plugs? Thanks
 
#22 ·
cjymiller, Camp, electricblue... do you guys feel you could have gone longer on those plugs? Thanks
I had about 10k miles on the outgoing plugs and yes, they could've safely gone another 5k safely without being replaced. Considering how much I hate doing the under the tank stuff it was worth it to replace with a longer interval plugs while everything was off. I ride 3-4k miles per year so this bought me several years before having to care about it again. Because my area can be so dusty with hot and cold extremes, I generally follow the more conservative schedules to be safe.

The new check interval will probably be almost 20k with the iridiums in, but for regular plugs you could probably just check around 15 and be fine.
 
#20 ·
I ran my original plugs for over 30,000 kms.

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#21 ·
I'm with you, people throwing away perfectly good plugs, i don't care how cheap they are, i guess it is the era we live in. I'm on my 8th motorcycle and never seen a plug go bad before 20k, unless it's faulty or something wrong with ignition system. I'm all four pulling and checking and cleaning and reinstalling, but new every year cmon!!

Sent from my N9810 using Tapatalk
 
#23 ·
The last time I priced Iridiums for the cage, it made me happy to replace ordinary plugs more often. Although, new cars coming with iridiums is fine, I've never done enough mileage to need to change them before we changed the car. The current car still has 46,000km to go.
 
#26 · (Edited)
Well, I'll be receiving my ecu today from vcyclenut, so i decided to change plus since i was in there anyway and wanted to see just how difficult it was, and its cake if you've ever changed plus before. Removing the ais is a 3 minute job. It's really not hard and they are easily accessible. Checked the clutch cable, as i read that it runs on the frame and i did find that mine was also. There was digging in the outer sheath, but did not look like it was going to rub through. I put a piece tape insulation there just to be good. Another thing i did was put electrical tape over ais outlet on air box and did the tube back over it. I know it's not really needed with the flash disabling the ais, but have heard it sometimes leaks so why not. At 18k, original plugs looked brand new and didn't need to be changed, totally intact,gaps were perfect, prefect color. Could have easily went another 5k.

Sent from my N9810 using Tapatalk
 
#27 ·
The first time I did this, it took 4 hrs going slow and learning. This time it only took 1.5 hrs and I spent time to take and add pics. This is a picture of the plugs with all 8k miles run with the Vcyclenut flash. I'm no expert, just putting the info out there.

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#29 ·
Has anyone confirmed that iridium plugs are ok for use on the XSR900 / FZ-09? I read in a couple of (seemingly reputable) places that, for some bikes, it's actually detrimental. I've used iridiums on several other bikes in the past with no issues, but would like to hear from anyone who's really looked into it. FWIW, I'm planning on swapping them at 6k (fairly soon) when I do the tb sync; probably every 10K - 12K thereafter.
 
#32 ·
Thank you. Best documentation of any process ever. I was totally put off reading descriptions of this task. If you came over and held my hand the whole time it might be better than this post. Thanks again.
 
#34 ·
This is a good thread. I am adding some comments on my experience. I have a 2017 with block off plates. I decided to drop the radiator to change the plugs. I used NGK CR9EIA-9, as recommended by NGK. (Not much more money than buying the OE CPR9EA-9)

MY steps:
1. Remove the side covers.
2. Remove the screws holding the top of the radiator
3. Unplug the spark plug wires
4. Twisting and pulling, remove the ignition coils
5. Remove the spark plugs
6. Install spark plugs, follow manufacturer guidelines for torque. I did hand tight and then 1/3 turn.
7. Reconnect the electrical parts.
8. Start the bike to check it.
9. Reassemble the rest.