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Topic: Honda 919 Spark Plug Removal  (Read 4006 times)

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« on: April 21, 2011, 09:15:52 PM »

So I went to replace the spark plugs on my 9er....  Shop manual says to raise the tank, check.  next remove the radiator bolts and slide forward, (doesn't say you have disconnect the upper radiator hose but there is no other way so get to it), check.  ok, easy to pull the wires and the plugs on cylinders 1 and 4, check.  2 and 3 OTOH  Mad2

Unless I'm missing something, there isn't enough room to pull the plug wires halfway out of the port before hitting the frame!  I am very frustrated with this, I don't see any way to get to the #2 or #3 plug without droppong the motor out of the frame.  I'm frustrated and going to bed.  If you have any ideas or if the magical mechanic gnomes could visit my garage and magically change out the plugs it'd be appreciated.

and here's a picture of the frame, the engine is a stressed member and it doesn't look like I could just swing it down around the rear motor mount, I think I may have to drop the whole thing.

http://i1126.photobucket.com/albums/l606/khuffy919/919frame.jpg
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« Reply #1 on: April 22, 2011, 09:04:08 AM »


Shame you're not closer. I'd do it for you.

1) the plug connectors  will bend and flex. They're just big rubber tubes. They may be stiff and aged and tight, but they WILL bend.

2) Using the factory spark plug socket, you'll be able to get the plugs out. If you try to use a conventional automotive socket, you'll likely never get it, or end up kicking the bike over. If you don't have the factory tool kit's plug socket, stop. Put it back together and order it from your HOnda dealer, look on eBay or see if you can borrow one here on ST.N.


Thanks for the response, the plug connectors don't bend that much but maybe I was being too gentle with it, after I slept on it I am willing to give it another try.  I don't have the factory plug socket, It wasn't in the regular tool kit that came with the bike.  How is the factory one different from mine?  is it a whole wrench / ratchet assembly?
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« Reply #2 on: April 22, 2011, 10:26:31 AM »

Just guessing, but I bet it has thinner walls than an automotive plug socket.
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« Reply #3 on: April 22, 2011, 10:46:24 AM »


Just guessing, but I bet it has thinner walls than an automotive plug socket.



Ya, probably some cheap pot-metal thing with a couple of holes in it for the rod they call the "breaker bar", but it's the only tool that works to get the plugs out.
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« Reply #4 on: April 22, 2011, 10:59:04 AM »

If I recall correctly, on the XX the only way to get the plugs out were with the factory wrench/socket that came in the tool bag. I'd be willing to wager the same is true for yours. Would be ridiculous to have to drop the engine from the frame.
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« Reply #5 on: April 22, 2011, 04:18:33 PM »

Sounds similar to the problem on some Ducatis.  One plug on my ST3 lives in a smaller diameter hole than the others and is also partially blocked by part of the frame.  A standard plug socket won't fit that one plug hole but will work for the other three.  Since I wanted a better quality socket than the one in the tool kit I had a machinist friend turn down one for me.
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« Reply #6 on: April 24, 2011, 10:00:38 AM »

All right, I definitely need the special wrench then.  When did they stop including all the tools you need in the factory tool pouch?   Thumbsdown
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« Reply #7 on: April 24, 2011, 11:55:27 AM »


All right, I definitely need the special wrench then.  When did they stop including all the tools you need in the factory tool pouch?   Thumbsdown


Weird, like you said, the shop manual for that bike makes no mention of a special tool needed. Just the steps you mentioned above like moving the radiator out of the way. Might need to ask a honda tech
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« Reply #8 on: April 25, 2011, 10:20:07 AM »

Looked it up in the owner's manual and there is supposed to be a spark plug wrench in the tool kit.  I bought my bike used and it must have disappeared before I bought it.....  Dealer told me the tool kit was complete but that's another story.......

Made a few calls and one of my buddies from back home knew a guy who totalled his 919.....  long story short, guy was a pack rat, never threw away anything, and didn't want anything for his tool kit.  A lot of running around, and I owe a couple of favors but I got the wrench.  Attempt number 2 coming up.

In case you're wondering what it looked like, I know I was curious
http://i1126.photobucket.com/albums/l606/khuffy919/2011-04-25_10-06-38_554.jpg
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« Reply #9 on: April 25, 2011, 11:11:43 AM »

Cool, glad you found one, and that is the exact same wrench that the XX had as well. It was the only way to get the plugs out. Crossing my fingers that round two goes better Smile
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« Reply #10 on: April 25, 2011, 08:07:27 PM »

Done, from seat removal to re-installation was 40 minutes.  Amazing when you have the right tool and the confidence of 'ok, it was impossible last time because I didn't have the correct wrench, I am not incompetant'.  Feels good to get that done, time for a brew and a good book.   Cool

Thanks for the advice, I won't hesitate to ask more dumb questions.
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« Reply #11 on: April 25, 2011, 09:46:33 PM »


Cool, glad you found one, and that is the exact same wrench that the XX had as well. It was the only way to get the plugs out. Crossing my fingers that round two goes better Smile


Yup.....for $15/plug you don't want to drop them either!!   Lol
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« Reply #12 on: April 26, 2011, 01:04:31 PM »


Unfortunately I've seen way too many "experienced" people answer questions like yours with insults and with deriding comments and with cockiness borne of being an "expert at everything". Never be afraid to ask - but always be willing to ignore the pricks.


+1 - I'm no expert either, I just happened to have had the same issue with a Honda bike before Smile
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« Reply #13 on: March 15, 2012, 06:00:04 PM »

Anyone in the boston area that wound consider loaning me the spark plug tool for a few hours Smile ?

I dont have one...
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« Reply #14 on: March 15, 2012, 08:01:56 PM »

I'm a couple hours from Boston.  Check out Wristtwisters.com.  All 919 all the time and there is a bunch of guys in the Boston area.  Good Luck!
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