How To: Change the spark plugs (03-05 R6)

You will need approx. 2 hours and some basic tools.
Here is what I used:



the socket size is 10mm, philips screwdriver (flat was used to lift the air filter cover), extensions, spark plug socket, not pictured there - 5mm hex and a piece of a line

1. remove the rear seat

2. remove the front seat using the 5mm hex, the screws are located at te back, under the seat





3. raise the tank, it is held by 2 hex type screws (5mm) in the front





4. Using a piece of a line secure the tank in a raised position by connecting the front of the tank with a bar under the rear seat



5. Remowe the air filter top cover - held by 6 philips screws



6. Remove the filer (it is a good time to change it too) and you may find that the previous owner put a k&n filter and velocity stacks for you



7. Remove the bottom of the air folter box, it is held by a 10mm bolt in the front



and some lines and electrical connector that are attached on the left



2 on the right



1 in the back



8. you will see that covering the spark plugs there is a heat shield - it's that black thing in front



you will have to remove it, I found that it is easier to do it if you lower the radiator a little bit, so unbolt the left side of the rad



and take the right side of the rad off too
now just work the heat shield out until it comes out, it is not hard, just take your time (it took me 5 minutes)



9. my advice - do the spark plugs one after another; start with # 2 and 3
unhook the electrical connector and pull the coil out by turning it a little bit



coil out



now you will need a spark plug socket and some extensions or a long spark plug socket, the latter is better cause there is no danger of disconnecting anything in your extensions, I used whatever I had though, it obviously has to be longer than a coil



it was tight but it worked



the first spark plug is out



replace it with the new one and thread it in, start with just your extensions, no wrench, just use your hand to make sure that you don't mess up a thread
now move to the next spark plug, the plugs 2 and 3 are easier to take out



10. get the spark plugs 1 and 4 out;
disconnect the electrical connectors



you can see the air line that will be in a way, disconnect it too, it is only held by a metal clamp





replace the plug, repeat the same thing to the other side, disconnect the electrical plug



disconnect the air line



and replace the spark plug
you now should have all the plugs out



11. when you reconnect the coils, while pushing them down make sure that you push them all the way down, until there is no gap between the rubber boot and the engine cover, they should "click" if pushed all the way, also make sure that you reconnected all the electrical connectors back to the coils, and all the air hoses (spark plugs 1 and 4)

12. reinstall the heat shield making sure that the rubber hoses go thru the same holes they were going thru before





13. put the botton of the airbox and reattach all the air hoses
on the left, 1 hose, 1 electrical connector



on the back 1 air hose



on the right 2 air hoses



and the bolt in the front



14. put the air filter in (change it prefferably) and put the cover back up, put all the 6 philips screws in



15. unhook the tank, put it down, screw it in

16. put back the front seat, screw it in

17. put back the rear seat

YOU ARE DONE!
CONGRATULATIONS!

Iam just putting this out there... I was able to change my plugs on the '99 w/o removing anything - gotta have small hands I guess and a plug socket that can "hold" the plug. I was also able to torque them to specs also. My knuckes were a little beat up after words.

Maybe this cant be done on a 2g - even with small hands though, dunno.

I had already change my plugs once before when I cleaned the carbs and I used this method, but I didn't feeling like going through it again.

Nice write up man. I gotta put plugs in my 04, but I keep putting it off cause it looks like so much damn work.

Good write-up, I have to change my plugs out before next riding season. Any tips on removing that heat shield - I see in the writeup you lowered the rad first, did the shield come out from top or bottom?

Just man handle that shield. Its pretty flexible and honestly I've never had trouble getting it out. Getting it back in can be a little bit of a PITA .

Yea putting that heat shield back in place is a huge PITA. The job as a whole isn't too bad though.

after lowering the rad the heatshield comes out from the top
and yup, putting it back is harder but by then you know how flexible it is

Originally Posted by pecha

after lowering the rad the heatshield comes out from the top
and yup, putting it back is harder but by then you know how flexible it is

I'll try that, thanks