Spark plug tool - check/change plugs

[AmyF]

I would really like to check/change my spark plugs today. Does anyone live anywhere near Niles Ohio that can let me perhaps borrow their spark plug tool or even recommend an alternative option for the plug removal using a "regular" spark plug wrench? My husband has one but I don't think it would work given the tight angle to reach the plugs. I really don't want to take the tank off - that concerns me.

[AmyF]

My husband has a spark plug tool that swings just like the one that comes in the tool kit (that I didn't get with my bike argh). It has a long skinny reach arm and a swivelling 13/16 spark plug socket. Is that the right "size" to get a hold of the plug?

[ninjamunky85]

If I remember correctly a 5/8" plug socket is what you need for the pre-gen. It's been a while since I've messed with the plugs on mine so I'm not certain.

But why are you so against removing the gas tank? It's super easy on these bikes, six screws and two lines I think, only takes about 5 minutes. Seems a lot easier to me than trying to fish out the sparks plugs with a tool.

[AmyF]

I got the tank off!!! I i have a 3/16 and this smaller one but it's not saying what size it is. It feels like it fits down in there but it's not pulling the plug

[ninjamunky85]

Is the plug loose? If it is then I've always used a magnetic pick up tool to get them out. Like this



If they aren't loose then it sounds like you need a different size socket.

[AmyF]

Looks like 5/8 is the right size socket so I'm gonna go grab that at the store and should be able to get to the plugs then

[AmyF]

Attached pics of the plugs after I went out and got the 5/8 socket. They look ok so I put them back in and everything back together. Only bad thing..I over toughened the one of the two tank screws that hold it onto the frame and it broke off in the hole. So it's fastened on tight by the one main screw and of course the fairings and the fuel lines are all good. Took it for a 15 min or so riel and it rode well.

[cuong-nutz]

Hard to see but from what I can tell it looks ok.

[agentbad]

Just make sure you stick with NGK if you replace them. That bolt size is 6x25 for the gas tank. It will be cheaper if you can find it in a local store but here it is on bikebandit. I actually need a lower fairing bolt but have it zip tied since I couldn't find a good replacement at lowes. Anyone know of a good spot to pick up fairing bolts for cheap?

http://www.bikebandit.com/2005-kawas...9183#sch433967

[AmyF]

For now I've just let it be and securely fastened the other tank bolt and the fairing bolts. How would I get that broken bolt piece out to put a new bolt piece in? If I just start screwing in the new bolt could I risk damaging it as it hits into the broken piece?

[ninjamunky85]

Yeah, you will need to get that bolt out. If I remember correctly that bolt just screws into a bracket. You'll have to at least partially remove the tank again to get to the bracket, but it should be easy to get the broken bolt out once you do.

[Desmoluci]

Originally Posted by AmyF

Only bad thing..I over toughened the one of the two tank screws that hold it onto the frame and it broke off in the hole.

First time I've heard it called that..

You'll probably have to drill it out. Centerpunch as close to center as you can, then start the hole with a small bit and work your way up. Then retap with a 6mm.

[Hero Danny]

When I had my pregen, I was removing my gas tank on a daily basis working on my damn carbs ...

[dcj13]

Originally Posted by Hero Danny

When I had my pregen, I was removing my gas tank on a daily basis working on my damn carbs ...

On my '03, the previous owner never dicked with the carbs. And neither have I. Runs great. YMMV.

[N-m]

Originally Posted by agentbad

That bolt size is 6x25 for the gas tank.
http://www.bikebandit.com/2005-kawas...9183#sch433967

Uh oh! I read that bolt should be 6X18 since anything longer will punch through the sidewall of the tank. I would go with the shorter of the two to be on the safe side.

Your local hardware store with a decent bolt bin would have these and they are cheap so you could buy more than one. Learn to feel what snug is, or invest in a small torque wrench.

[PHMCS]

When I got mine, the left tank bracket bolt was sheared off as well, while the other snapped as I was attempting to loosen it. I've just resigned myself to the fact that while I love my bike, kawasaki uses some of the worst fasteners on earth for the 250.

I unbolted the bracket from the frame and managed to work out the broken half with some pliers and a bit of wd40 in an effort to avoid drilling it. If it has any sticking out of the bottom of the bolt hole, it may be worth a shot.

If you haven't replaced it in a few weeks, let me know, and I'll likely have a few replacement bolt kits in stock.

I don't think there was a single bolt on my bike that wasn't stripped to the point of uselessness, or rusted to the point of crumbling, so I finally snapped myself and replaced the tank bracket and fuel filler cap with forged titanium bolts for their anti-corrosion properties. Horrible investment yes, but almost two years later they still look brand new despite being constantly exposed to the elements and being taken on and off a hundred times. In retrospect, stainless would've done the same thing, but I wanted to do something nice for her.

[dcj13]

Originally Posted by PHMCS

...so I finally snapped myself and replaced the tank bracket and fuel filler cap with forged titanium bolts for their anti-corrosion properties.

Another strategy is to get regular steel fasteners and put a light coating of anti-seize compound (or even grease) on the fastener thread prior to insallation (or reinstallation). Only needs to be done one time.

[agentbad]

Originally Posted by N-m

Uh oh! I read that bolt should be 6X18 since anything longer will punch through the sidewall of the tank. I would go with the shorter of the two to be on the safe side.

Your local hardware store with a decent bolt bin would have these and they are cheap so you could buy more than one. Learn to feel what snug is, or invest in a small torque wrench.

You're right about the side screws I thought he was talking about the top screws under the seat.

[N-m]

Originally Posted by PHMCS

I've just resigned myself to the fact that while I love my bike, kawasaki uses some of the worst fasteners on earth for the 250.

I don't think there was a single bolt on my bike that wasn't stripped to the point of uselessness, or rusted to the point of crumbling

They use the same hardware many other companies use, and I use, with no problems. This was a problem caused by the previous owner.

[DmbShn41]

To get the broken bolt out, before you start drilling it out, try and turn it out with a small screwdriver, slotted of course. Sometimes with a broken bolt you get lucky and can un thread it out easily. If its cross threaded, then thats a whole other ball game...

[amad1972]

As long as you had the plugs out, why didn't you just put new ones in? I did this a few days ago, and the NGK plugs were only a couple bucks each.