DemonRR
06-28-2008, 04:12 PM
this is a DIY for changing out spark plugs on a 2004 1000rr. the same basic principals apply to most bikes.
this was relativity an easy thing to do, but a little tricky to accomplish. the service manual says to go from the front of the bike. they say by lowering the radiator and removing the front air intake you can change the plugs from there. i tried this and it was a tight
fit working in the small area. i was also doing the pair mod at this time and found that you have alot more rooom by going thru the airbox to change out the plugs. i chose to go from the top. i was doing the pair mod at this time.
i already have all the fairings/tank cover off from other mods im doing.
1.remove the fuel drain tube and 2 front gas tank bolts
2.rotate the fuel tank back and support with a block of wood
3.remove the 6 phillips screws from the top of the airbox and disconnect the IAT sensor. now remove the top lid and remove the filters
4. disconnect all 4 injector connections and remove the 2 screws that hold down the harness. set outside of bike. unbolt the 6 bolts that held the injector rail to the airbox. they will have yellow paint on the tops. now lay the injector rail out of the way.
5. remove the other screws around the airbox. i think there were 7. now remove the middle section of the airbox.
6. remove the 6 screws around the velocity stacks, now remove the stacks. they can only go back on 1 way so dont wory if you got them mixed up. unscrew the 6 bolts around the airfilter holes (the screws are shiney/gold looking)
7. remove the lower section of the airbox
8. remove the 4 bolts that hold the radiator in place. 1 is by the radiator cap, 1 is by the overflow tank lid, and the last two are underneath inbetween the middle header pipes.(the radiator support bracket)
9. carefully slide the radiator to the left and down. dont damage any of the fins on the radiator.
10. there are 2 allen bolts that attatch the front of the airbox. remove these bolts
11. now remove the 2 air duct screws on the sides.
12. pull the airduct out twords the rad and front tire. its ok if you cant fully remove it1
13. back up top, remove the innner air duct. this exposes the top of the valve cover for easy access to the plugs. i also did the pair mod while i was here. that will be in another DIY.
14. remove the 4 coil pack connectors
15. remove the 4 coil packs. you might have to pull a bit hard as they dont just pop out easily.
15. i used the supplied (oem tool kit) spark plug wrench and removed all 4 plugs
16. install the new plugs finger tight, then a 1/4 turn with a wrench. DO NOT OVER TIGHTEN!!!!!
17. now repeat the process in reverse order.
i tried it the way the service manual said to do. but i ran into an issue. i could not seperate the front of the air duct from the inner air duct. there is a sorta "L" bracket to help align the 2. so i had to go from the top to seperate the 2 air duct pieces.
this was relativity an easy thing to do, but a little tricky to accomplish. the service manual says to go from the front of the bike. they say by lowering the radiator and removing the front air intake you can change the plugs from there. i tried this and it was a tight
fit working in the small area. i was also doing the pair mod at this time and found that you have alot more rooom by going thru the airbox to change out the plugs. i chose to go from the top. i was doing the pair mod at this time.
i already have all the fairings/tank cover off from other mods im doing.
1.remove the fuel drain tube and 2 front gas tank bolts
2.rotate the fuel tank back and support with a block of wood
3.remove the 6 phillips screws from the top of the airbox and disconnect the IAT sensor. now remove the top lid and remove the filters
4. disconnect all 4 injector connections and remove the 2 screws that hold down the harness. set outside of bike. unbolt the 6 bolts that held the injector rail to the airbox. they will have yellow paint on the tops. now lay the injector rail out of the way.
5. remove the other screws around the airbox. i think there were 7. now remove the middle section of the airbox.
6. remove the 6 screws around the velocity stacks, now remove the stacks. they can only go back on 1 way so dont wory if you got them mixed up. unscrew the 6 bolts around the airfilter holes (the screws are shiney/gold looking)
7. remove the lower section of the airbox
8. remove the 4 bolts that hold the radiator in place. 1 is by the radiator cap, 1 is by the overflow tank lid, and the last two are underneath inbetween the middle header pipes.(the radiator support bracket)
9. carefully slide the radiator to the left and down. dont damage any of the fins on the radiator.
10. there are 2 allen bolts that attatch the front of the airbox. remove these bolts
11. now remove the 2 air duct screws on the sides.
12. pull the airduct out twords the rad and front tire. its ok if you cant fully remove it1
13. back up top, remove the innner air duct. this exposes the top of the valve cover for easy access to the plugs. i also did the pair mod while i was here. that will be in another DIY.
14. remove the 4 coil pack connectors
15. remove the 4 coil packs. you might have to pull a bit hard as they dont just pop out easily.
15. i used the supplied (oem tool kit) spark plug wrench and removed all 4 plugs
16. install the new plugs finger tight, then a 1/4 turn with a wrench. DO NOT OVER TIGHTEN!!!!!
17. now repeat the process in reverse order.
i tried it the way the service manual said to do. but i ran into an issue. i could not seperate the front of the air duct from the inner air duct. there is a sorta "L" bracket to help align the 2. so i had to go from the top to seperate the 2 air duct pieces.