lotus
.040 Over
Old man winter has appeared in my part of Colorado putting a stop to riding until Spring. The coup de grace was the highway department
throwing down mounds of a deadly combination of sand, gravel and Mag Chloride onto my favorite roads. The magnificent beast is in the heated garage
demanding attention since it's 4k miles beyond the 20k service. I've changed all the fluids, air filter and just completed changing the spark plugs.
I won't do the valve adjust for now. More than I want to tackle at this point. I'll probably pay the dealer to do it at some point in the future.
Some general comments about the plug change from a person that has never done it before:
* I called my local Triumph dealer and asked how much to only change the plugs. Was told ~$360 including labor, plugs and tax.
* I would recommend doing this on the side stand. I know a lot of you have lifts, but lifting the gas tank, balancing and disconnecting
a difficult connector at a high position would be difficult. Also, the downward pressure required to properly seat the rubber plug caps would
be difficult at shoulder height. I had to use all my body weight to get them to seat. More about this later.
* Take lots of pictures once tank is off for use at reassembly.
* I would allow 4 hours to the job. Hopefully your reading this would make it shorter.
* I went with the NGK Iridium plugs (LMAR8BI-9 $18.49ea) for longevity reasons. I don't want to do this again. Stock plugs are NGK - LMAR8A-9 $7.99ea).
* There's been some irritation from other riders about the boots being loose. All six of mine were NOT properly seated. They were just sitting loose
on the valve cover and no effort was required to pull the boots out. Surprisingly, this didn't seem to have any effect on the bike. It never
missed or mis-behaved. All was normal. See pic of plugs I pulled out with 24k miles. Even the plug terminals were fine. The only indication of arcing(?)
is a dark discoloration. The spark ends of all but one, were perfect with correct gap. One plug was a little "crusty" suggesting fuel delivery issue? It was
suggested running some injector cleaner on next fill up. I started out placing the plugs by position on the floor to match plug to cylinder. Studying each
plug would give me an idea if the cylinder was running rich or lean. However, as I was wrestling with the plug change I unknowingly kicked the pile
scattering the plugs. I have no idea which cylinder the 'crusty' plug came out of.
* Have access to the tech manual (not the owners manual) for removing tank, etc.
What you'll need (see pic) to do this job
* 14mm articulated plug socket. This is a MUST have with magnetic hold and getting past all the stuff that's in the way.
Here's the Amazon link -> Amazon.com
Many thanks to journeyman for finding and sharing
* Torque wrench for plug
* Six Iridium spark plugs At ~$20 ea
* Two 90 deg picks to remove the fuel connector from fuel rail. Cursing will be required. Note that tech manual tells you to slid latch to
to outside and press sides while pulling up. The "latch" is NOT a mechanical release. It's only a cover for the release
buttons on both sides. You'll have to use the 90deg picks to press in at the same time while pulling up.
* Wood board to jam under tank when disconnecting fuel line. Before removing tank, release pressure by cracking open gas cap.
Once you get the fuel line removed, only a tablespoon of gas will be released.
* 4mm and 5mm allen wrenches.
* 12mm socket for removing forward charcoal canister bracket
* 11mm right angle box end wrench that is modified (cut) to allow ignition lead to slip through. This will be used to press down
on the spark plug boot. See attached picture
* Dielectric grease applied to boot top. Found useful to allow the boot to more easily be pushed into the valve cover hole.
* Anti-Seize for plug threads. Understand NGK doesn't recommend, but being old school, I feel better about using it. If you do use it, apply sparingly
and be sure to reduce the torque value by 25%. This would take it from 12nm to ~9nm. Your preference.
Now to the steps.....
1) Disconnect battery. Don't be lazy about this. You'll be disconnecting coil wires and brackets not knowing where the wires will end up.
2) When removing the tank, understand there are 3 things that need to be removed. Charcoal canister hose on right/forward side, electrical
connector under tank and fuel rail connector behind master switch. The electrical connector will require cursing to get it apart. Also, the
connector is clipped to the top of frame via a tab/slot. DON'T try to separate the connector while attached to the frame because there's
not enough wire length when tank is resting in seat location. You'll break the plastic frame tab like I did. You need to first slide connector
assembly to the rear to detach from frame. Once the connector is removed from the frame, there are 3 points to press to get it to separate.
This is where the cursing is used to separate three tabs with two hands. Be patient.
3) Unbolt top coil pack pair bracket and move aside.
4) Unbolt the coil and bracket on right side.
5) Remove the charcoal canister which requires unbolting a bracket. Move aside
Note: Brake distribution block does not have to be touched.
6) Remove/replace one plug at a time moving from rear --> forward. The rear plug is most accessible allowing you to get a "feel" for what to expect as
you move forward. This will also insure you don't mix up the ignition wire positions. Also, before removing the plug, blow out any debris that might
be hiding at the bottom.
7) Apply anti-seize (optional) and insert plug and tighten to 9nm. Reduced torque because of anti-seize. 12nm for "dry" plug.
8) Before putting rubber boot in the hole, take the removed plug and push it into the boot to make sure it goes in and out OK. I found one of mine could
not be inserted because the spring connector inside the boot was out of alignment. Maybe this is why the line workers didn't get them seated properly?
Anyway, make sure the boot will accept the plug terminal.
9) Drop the boot into the hole. Now take the 11mm modified box end and position against the top of the rubber cover (see pic). Now use your weight to press down until you hear a "crunching" sound. This is the threaded terminal end moving through the spring. When you hear the crunch stop, you've got it. Remove the wrench and notice the rubber cover in the hole. It should NOT be flat, but pushed down somewhat into the hole (see pic 'Seated vs Not'). In the pic, properly seated is on left, not seated on right.
10) Repeat 5 more times....
11) Reassemble using pictures as necessary. I took the time to make sure the routing of the leads were not under stress or against sharp bracket edges.
12) Start the bike and give it time to charge the fuel rail before firing.
13) While it's running, you'll notice the service light (wrench symbol) will be showing in the display. This is caused by disconnecting and reconnecting the
battery. Clear by going into the home screen and resetting the clock & calendar.
Have a beer and pat yourself on the back.......
throwing down mounds of a deadly combination of sand, gravel and Mag Chloride onto my favorite roads. The magnificent beast is in the heated garage
demanding attention since it's 4k miles beyond the 20k service. I've changed all the fluids, air filter and just completed changing the spark plugs.
I won't do the valve adjust for now. More than I want to tackle at this point. I'll probably pay the dealer to do it at some point in the future.
Some general comments about the plug change from a person that has never done it before:
* I called my local Triumph dealer and asked how much to only change the plugs. Was told ~$360 including labor, plugs and tax.
* I would recommend doing this on the side stand. I know a lot of you have lifts, but lifting the gas tank, balancing and disconnecting
a difficult connector at a high position would be difficult. Also, the downward pressure required to properly seat the rubber plug caps would
be difficult at shoulder height. I had to use all my body weight to get them to seat. More about this later.
* Take lots of pictures once tank is off for use at reassembly.
* I would allow 4 hours to the job. Hopefully your reading this would make it shorter.
* I went with the NGK Iridium plugs (LMAR8BI-9 $18.49ea) for longevity reasons. I don't want to do this again. Stock plugs are NGK - LMAR8A-9 $7.99ea).
* There's been some irritation from other riders about the boots being loose. All six of mine were NOT properly seated. They were just sitting loose
on the valve cover and no effort was required to pull the boots out. Surprisingly, this didn't seem to have any effect on the bike. It never
missed or mis-behaved. All was normal. See pic of plugs I pulled out with 24k miles. Even the plug terminals were fine. The only indication of arcing(?)
is a dark discoloration. The spark ends of all but one, were perfect with correct gap. One plug was a little "crusty" suggesting fuel delivery issue? It was
suggested running some injector cleaner on next fill up. I started out placing the plugs by position on the floor to match plug to cylinder. Studying each
plug would give me an idea if the cylinder was running rich or lean. However, as I was wrestling with the plug change I unknowingly kicked the pile
scattering the plugs. I have no idea which cylinder the 'crusty' plug came out of.
* Have access to the tech manual (not the owners manual) for removing tank, etc.
What you'll need (see pic) to do this job
* 14mm articulated plug socket. This is a MUST have with magnetic hold and getting past all the stuff that's in the way.
Here's the Amazon link -> Amazon.com
Many thanks to journeyman for finding and sharing
* Torque wrench for plug
* Six Iridium spark plugs At ~$20 ea
* Two 90 deg picks to remove the fuel connector from fuel rail. Cursing will be required. Note that tech manual tells you to slid latch to
to outside and press sides while pulling up. The "latch" is NOT a mechanical release. It's only a cover for the release
buttons on both sides. You'll have to use the 90deg picks to press in at the same time while pulling up.
* Wood board to jam under tank when disconnecting fuel line. Before removing tank, release pressure by cracking open gas cap.
Once you get the fuel line removed, only a tablespoon of gas will be released.
* 4mm and 5mm allen wrenches.
* 12mm socket for removing forward charcoal canister bracket
* 11mm right angle box end wrench that is modified (cut) to allow ignition lead to slip through. This will be used to press down
on the spark plug boot. See attached picture
* Dielectric grease applied to boot top. Found useful to allow the boot to more easily be pushed into the valve cover hole.
* Anti-Seize for plug threads. Understand NGK doesn't recommend, but being old school, I feel better about using it. If you do use it, apply sparingly
and be sure to reduce the torque value by 25%. This would take it from 12nm to ~9nm. Your preference.
Now to the steps.....
1) Disconnect battery. Don't be lazy about this. You'll be disconnecting coil wires and brackets not knowing where the wires will end up.
2) When removing the tank, understand there are 3 things that need to be removed. Charcoal canister hose on right/forward side, electrical
connector under tank and fuel rail connector behind master switch. The electrical connector will require cursing to get it apart. Also, the
connector is clipped to the top of frame via a tab/slot. DON'T try to separate the connector while attached to the frame because there's
not enough wire length when tank is resting in seat location. You'll break the plastic frame tab like I did. You need to first slide connector
assembly to the rear to detach from frame. Once the connector is removed from the frame, there are 3 points to press to get it to separate.
This is where the cursing is used to separate three tabs with two hands. Be patient.
3) Unbolt top coil pack pair bracket and move aside.
4) Unbolt the coil and bracket on right side.
5) Remove the charcoal canister which requires unbolting a bracket. Move aside
Note: Brake distribution block does not have to be touched.
6) Remove/replace one plug at a time moving from rear --> forward. The rear plug is most accessible allowing you to get a "feel" for what to expect as
you move forward. This will also insure you don't mix up the ignition wire positions. Also, before removing the plug, blow out any debris that might
be hiding at the bottom.
7) Apply anti-seize (optional) and insert plug and tighten to 9nm. Reduced torque because of anti-seize. 12nm for "dry" plug.
8) Before putting rubber boot in the hole, take the removed plug and push it into the boot to make sure it goes in and out OK. I found one of mine could
not be inserted because the spring connector inside the boot was out of alignment. Maybe this is why the line workers didn't get them seated properly?
Anyway, make sure the boot will accept the plug terminal.
9) Drop the boot into the hole. Now take the 11mm modified box end and position against the top of the rubber cover (see pic). Now use your weight to press down until you hear a "crunching" sound. This is the threaded terminal end moving through the spring. When you hear the crunch stop, you've got it. Remove the wrench and notice the rubber cover in the hole. It should NOT be flat, but pushed down somewhat into the hole (see pic 'Seated vs Not'). In the pic, properly seated is on left, not seated on right.
10) Repeat 5 more times....
11) Reassemble using pictures as necessary. I took the time to make sure the routing of the leads were not under stress or against sharp bracket edges.
12) Start the bike and give it time to charge the fuel rail before firing.
13) While it's running, you'll notice the service light (wrench symbol) will be showing in the display. This is caused by disconnecting and reconnecting the
battery. Clear by going into the home screen and resetting the clock & calendar.
Have a beer and pat yourself on the back.......
Attachments
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Tank Off to Start.jpg204 KB · Views: 73
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Tools Needed.jpg338.3 KB · Views: 68
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Bracket Removed.jpg217.5 KB · Views: 69
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Before Replacing.jpg213.7 KB · Views: 69
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Tool 1.jpg134.3 KB · Views: 70
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Tool In Place 2.jpg106.3 KB · Views: 73
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Seated vs Not.jpg104 KB · Views: 75
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All Plugs Installed.jpg155.7 KB · Views: 75
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Old Plugs.jpg171.4 KB · Views: 73
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