Its fucked

[AcIdBuRnZ]

Hi,

Had been meaning to change the spark plugs for a while now. Got all the tools together that I needed and started...

Catalogue of fuck ups from the off:

Took long enough to figure out how to remove the tank (you think it could have been easier - Haynes manual is shit)

A screw holding one of the side panels had to be drilled out - it was so bloody tight it rounded so I had no other option.

Plug holes full of crap so got hoover to clean out most of it.

Got one of the plugs out - it was completely fucked, I'm surprised that it started at all!

Put in new plug - but I don't think that its' going down all the way.

Then attached HT lead and tried to start it - only firing on the other cylinder. Bugger.

Made sure HT lead was on properly - then it fell apart. That's right, the end of the HT lead was only just pushed together!!! Fuck me!

So basically I have two problems:

1) How can I make sure the plug is seated correctly.

2) Where (and how much?) can I get a set of HT leads for a 1998 ER-5.

I well pissed off. No bike and no money to take it to a garage

Any one got any ideas?
____________________
Past: Honda NSR125R >> Kawasaki ER-5a2 >> Kawasaki ZZR-600e1 >> Suzuki GSXR-750Y >> Honda VTR 1000 Firestorm
"Chickity China the Chinese Chicken..."

[Scotsman37]

You can buy any new replacement OEM parts for a Kawasaki from Z Power, but they don't list everything on their homepage and so contact them by e-mail with a full description of the bike ie year & model and explain to them what you need. They will contact you within 24 hours with a price for the repalcement.

www.z-power.co.uk

[AcIdBuRnZ]

You are a legend

Cheers mate, I've just sent them an email.

Mark
____________________
Past: Honda NSR125R >> Kawasaki ER-5a2 >> Kawasaki ZZR-600e1 >> Suzuki GSXR-750Y >> Honda VTR 1000 Firestorm
"Chickity China the Chinese Chicken..."

[Guest]

You can buy replacement plug caps in various shapes .......

https://www.dirtbikestore.co.uk/acatalog/plugcap.JPG

Just cut the old one off and screw the new one into the end of the HT lead.



Of course, if your bike has those fancy combination leads and coils just ignore what I say

[stinkwheel]

Make sure there is no junk under where the plug is supposed to seat, a lump of blue-tak on the end of a screwdriver is useful for this. Now screw the plug in by tightening it 1/2turn, loosening 1/4 turn, tightening 1/2 turn, loosening 1/4 turn. This should clean any junk out of the threads and reseat any that are slightly bent.

Do not force it!
____________________
“Rule one: Always stick around for one more drink. That's when things happen. That's when you find out everything you want to know.”
I did the 2010 Round Britain Rally on my 350 Bullet. 89 landmarks, 3 months, 9,500 miles.

[AcIdBuRnZ]

Cool, cheers Stinkwheel

Gonna order a new set of leads then have another bash. Not in any rush for the bike (rideout on the 13th Feb).

I hate it when simple jobs turn out to be the worst
____________________
Past: Honda NSR125R >> Kawasaki ER-5a2 >> Kawasaki ZZR-600e1 >> Suzuki GSXR-750Y >> Honda VTR 1000 Firestorm
"Chickity China the Chinese Chicken..."

[instigator]

Mark - totally wish you'd told me about this before, could have saved you an age.

I've taken the tank off about 10-15 times now, and first time it took about 30 minutes, now, approximately one minute if you don't have to take the tank RIGHT off the bike, and 4 minutes if you do. The fuel tap is a right fidgety bastard to move around the frame and engine block. Its all in the technique relaly, ones you've got it, its easy.

And the right hand spark plug is a real bother to get out because of the coolant pipework. I wonder how the helll they managed to get away with planning that one????

My screws holding the mid fairings have almost rounded off as well (common fault) and believe it or not, I believe one of my plug caps is done for. Managed to bodge it on but its not very secure. The original ones are stupidly cheap and nasty, thinking of ordering myself some NGK ones instead.

Really pisses you off, doesnt it

[AcIdBuRnZ]

Never thought you'd have had much time to play with the mechanics of the bike Greg - I've had mine almost a year!

Never had a reason to remove tank until now.

I removed the tank and turned it 90 degrees to rest across the bike - that how you do it?

Anyway, needing new HT leads. Can't do nothing until they arrive.

Pissed off - I hate leaving a job unfinished
____________________
Past: Honda NSR125R >> Kawasaki ER-5a2 >> Kawasaki ZZR-600e1 >> Suzuki GSXR-750Y >> Honda VTR 1000 Firestorm
"Chickity China the Chinese Chicken..."

[instigator]

[AcIdBuRnZ]

Hmm, I tried to remove my oil filter a while back but it won't budge. Changed the oil though (well kinda had to since I had drained it).
____________________
Past: Honda NSR125R >> Kawasaki ER-5a2 >> Kawasaki ZZR-600e1 >> Suzuki GSXR-750Y >> Honda VTR 1000 Firestorm
"Chickity China the Chinese Chicken..."

[Scotsman37]

Would it not move even with a torque/socket wrench?

It must have been over tightened without the use of a torque wrench.

[kasandrich]

Use a chain wrench, that'll shift it.
____________________
Richard

CBR1000FM

[AcIdBuRnZ]

[kasandrich]

^^^^or a sharp'sh screwdriver, and tap a notch into the rolled edge, then try and tap it around with the hamer and screwdriver.
____________________
Richard

CBR1000FM

[mchaggis]

[bish777]

[Scotsman37]

You know what you might have to do? Take it to a mechanic/welder with welding epuipment so that he can spot weld onto the filter plug temporarily a steel bar and then you will be able to remove it so as to do your oil filter change. I would highly recommend getting a replacement filter plug and buy a torque wrench and smear some engine oil on the plug's threading to prevent future seizing !

[stinkwheel]

[AcIdBuRnZ]

[stinkwheel]

[Kickstart]

[AcIdBuRnZ]

Cheers guys, you really have helped me understand a bit better.

I'll try the suggestion of cutting a bit off the lead and screwing it back in again. Hopefully should work!!!

Fingers crossed, I'll keep you posted
____________________
Past: Honda NSR125R >> Kawasaki ER-5a2 >> Kawasaki ZZR-600e1 >> Suzuki GSXR-750Y >> Honda VTR 1000 Firestorm
"Chickity China the Chinese Chicken..."

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[stinkwheel]

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