Spark Plug Maintenance |
Proper working spark plugs are an essential part of any well maintained and properly running bike/scooter. You can check the maintenance chart below to see what the Suzuki recommended service intervals are.
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Qty | Parts List | Price |
2 | NGK CR8E for standard temperatures | $9 |
Spark Plug Heat Range Check List | ||||||||||||
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Time: | 1-2 hours | Difficulty level: | Medium |
Tools | Description |
Ratchet | Any size will do as long as you have the right size sockets for it, 3/8" is ideal A 1/4" is even better for this job considering the limited work space behind the radiator |
Sockets | 8mm 10mm 14mm |
Bungee cords | 2 small bungee cords |
Plastic Tubing | 5" piece of plastic tubing |
Spark Plug Tool | A spark plug tool should have come with your OEM tool bag |
Paper towel | For cleaning. |
Torque Wrench | A 1/4" would be ideal due to the limited space but a 3/8" would also work |
Tools and Parts Picture | |
Note: I have switched to a 5k service interval now that the extended warranty on my 2004 burgman 650 has expired. I am going to change my plugs every 10k miles from here on.
Note: Changing the spark plugs on the Burgman 650 is probably one of its most tedious/challenging maintenance tasks. Not so much because it s a difficult procedure but mainly because of the limited/confined space in which one has to perform the job. So be patient and you will be able to get through it rather easily. |
Step | Description | Pictures |
1. | Start by putting the scooter on the center stand. | |
2. | Remove the Radiator cover / rad. It is held in place by two small snap in plastic rivets and two screws. Don't try force out the plastic rivets, they seem to be a permanent. | |
3. | Remove the radiator bolt with a 10mm socket. | |
4. | Push your front wheel out of the way. If you are not going to remove the front fender I would recommend that your place a towel over the back of it to prevent any accidental scaring that could occur from the radiator rubbing against it. | |
5. | Pull the radiator out gently and hold it open by using a small bungee cord. | |
6. | Undo the radiator boot/cover tabs on both side of the radiator and remove it carefully. | |
7. | Unplug the wires from the spark plug ignition/coil caps. Remove the wire from the wire hook between the two caps. | |
8. | I decided to remove the wire hook in order to give myself a bit more operating room. Use an 8MM socket. | |
9. | Pull out the ignition/coil caps, there are two of them. Be careful not to hit your radiator from behind and damage the fins. | |
10. | Insert the spark plug tool from your tool bag. Use a 14mm socket to loosen the plug. Finish the process by hand as there just isn't a lot of room back there to operate a ratchet/wrench. Once the plug is loose, pull it out gently and put it aside. Repeat the process for the other plug. | |
11. | Replace the plugs with new ones or clean the old ones and inspect them before reinserting them. I replaced mine, considering the amount of work it takes to get to them. | |
12. | Insert the new plug into the spark plug tool ( or use a piece of plastic tubing ) to rethread the plug back into place. Repeat for the other plug |
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13. | Tighten plugs to the specified Torque setting 8.0 lb-ft, 11 N-m, 1.1 kgf-m using a 14mm socket | |
14. | Reinsert the ignition/coil caps back into place. | |
15. | Plug the wires back into the ignition/coil caps. | |
16. | Reinstall the cable support hook if you had removed it using an 8mm socket Reinsert the cable onto the cable support hook | |
17. | Reinstall the radiator boot/cover and snap in the tabs on each side. Make sure you have a good tight fit. | |
18. | Remove the bungee cord, move the radiator forward and reinstall and tighten the radiator bolt using a 10mm socket. | |
19. | Reinstall the radiator cover / rad using the two phillips screws and the two snap-ins. |
