KLR spark plug change fail.

Discussion in 'Thumpers' started by Mikef5000, Jul 10, 2011.

  1. Mikef5000

    Mikef5000 Long timer

    Joined:
    Apr 17, 2008
    Oddometer:
    2,138
    Location:
    Columbus, OH
    2009 KLR650 - 13k miles

    Alright, so all my spark plug sockets are too fat to fit in the recess in the head. I get online and google search to find that there is a spark plug tool in the tool kit. I get out the tool, and it's too long to fit! It hits the frame above the spark plug. It seems a good 2 inches longer than it needs to be. I could probably hammer it in there, but there's no way I'd be able to unthread it with the tool being pressed in beneath the frame to begin with.

    I already have the gas tank and side panels off and out of the way (for other projects).

    Has anyone else experienced this? What am I missing? I'm thinking of cutting an inch or so off the end of the tool.

    I took pictures but can't upload them at the moment.

    Thanks!
    #1
  2. Mikef5000

    Mikef5000 Long timer

    Joined:
    Apr 17, 2008
    Oddometer:
    2,138
    Location:
    Columbus, OH
    [​IMG]

    Tool is pressed into the frame at the top, yet still at to much of an angle to seat over the plug.
    #2
  3. beeper

    beeper Badger tickler

    Joined:
    Sep 2, 2009
    Oddometer:
    823
    Location:
    Wisconsin
    I'd trim the tool. :deal
    #3
  4. Velour Fog

    Velour Fog Pants optional

    Joined:
    Apr 1, 2011
    Oddometer:
    100
    Location:
    Port Hedland - Western Australia
    G'Day,
    I bought a tube/long socket and then ground it down till it was thin enough to be able to fit in there..
    #4
  5. Gray_Rider

    Gray_Rider Been here awhile

    Joined:
    Jul 14, 2010
    Oddometer:
    270
    Location:
    Richmond, NSW
    It doesn't look like the spark plug spanner I got with my early model. Mine is much shorter .

    Any other KLR riders comment?

    Either way before you pull the plug, blow out all the sand and dust around it, otherwise it all goes in the cylinder!
    #5
  6. Beezer

    Beezer Long timer Supporter

    Joined:
    Oct 26, 2004
    Oddometer:
    12,155
    Location:
    Anchorage, formerly Spenard (hub of the universe)
    the one that came with my 05 works fine.... no real dif in the bikes, so?????
    #6
  7. Gray_Rider

    Gray_Rider Been here awhile

    Joined:
    Jul 14, 2010
    Oddometer:
    270
    Location:
    Richmond, NSW
    Accordind to the part fiche, there should be 2 tube spanners - #92110A and #92110B.

    There all the same for every year model.

    Is there another tube spanner in your kit?

    P.S. I wouldn't cut it, the other end will fit some other part of your bike.
    #7
  8. Kawidad

    Kawidad Long timer

    Joined:
    Jul 9, 2005
    Oddometer:
    6,620
    Location:
    Central Coast, Cal
    Looks like the spark plug tool that with the kit in my KLX300. :dunno
    #8
  9. crypto666

    crypto666 Long timer

    Joined:
    May 30, 2011
    Oddometer:
    1,994
    Location:
    ho chi min
    You could notch the frame, but I would probably trim the tool. They are a dime a dozen, I have several of those that came with various bikes/atvs and have yet to find them useful.
    #9
  10. itsatdm

    itsatdm Long timer

    Joined:
    Jun 19, 2004
    Oddometer:
    5,440
    Location:
    Nor Ca.
    I was going to say, that is what i need for a KLX650, a very deep well and no back bone to get in the way.
    #10
  11. oneblackdog

    oneblackdog slowest of the slow

    Joined:
    Mar 7, 2009
    Oddometer:
    187
    Location:
    Moggill, Qld, Australia
    :baldy:eek2

    That's not the s/plug socket.

    The plug socket has a closed top which takes the 17mm spanner, is much thicker (what you have is the probably the 12mm socket, while the plug is approx 18mm), and has a rubber insert to catch the plug top.

    Have another look in the kit, as you need that one, as bought sockets are usually to thick to fit in the small whole surrounding the plug.

    Good luck.

    OBD
    #11
  12. Mikef5000

    Mikef5000 Long timer

    Joined:
    Apr 17, 2008
    Oddometer:
    2,138
    Location:
    Columbus, OH
    Alright, so this bike came with two tool kits. A small one that fits in the luggage rack, as well as a slightly larger one that is separate from the bike. It appears to me that he (owner of the bike) wasn't even supposed to get this separate larger tool kit. It has several tools that do not fit his bike; this spark plug 'socket', some axle wrenches, and even a couple spanner wrenches.

    Going back through the small tool kit in the luggage rack I found the second spark plug socket that got the job done.

    All good now. Back together with a new (and gapped) iridium plug, plus the subframe bolt upgrade, new fog-lights, a couple relays to control the heated grips and lights, and new brake pads.

    Thanks!
    #12
  13. vanaman

    vanaman Been here awhile

    Joined:
    Nov 15, 2009
    Oddometer:
    194
    Location:
    Around Columbus Ohio
    hi mike
    #13
  14. Mikef5000

    Mikef5000 Long timer

    Joined:
    Apr 17, 2008
    Oddometer:
    2,138
    Location:
    Columbus, OH
    Hello Steve.
    #14