Can't Remove Spark Plug - Suzuki Burgman Forum
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Old 04-18-2009, 05:34 PM   #1 (permalink)
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Default Can't Remove Spark Plug

I tried changing the plug on my '07-400 and when I push in the socket set it would bounce around so in put a light to it and notice that there is a thin rubber sleeve around it and
absolutely cannot get the socket in.

Any experience this and have any suggestions?

Thx
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Old 04-18-2009, 06:16 PM   #2 (permalink)
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Default Re: Can't Remove Spark Plug

Sounds like the rubber grip from inside the spark plug socket came off and stayed on your spark plug. You should be able to slowly rotate the socket until it fits down on the plug and turn it and pull it out plug and all. I know mine the spark plug tool did that when I was trying to get it out and it was annoying.
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Old 04-18-2009, 09:33 PM   #3 (permalink)
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Default Re: Can't Remove Spark Plug

You can grab the rubber thingee with some long needlenose pliers and yank it out. Just be careful not to damage the plug.
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Old 04-19-2009, 11:48 AM   #4 (permalink)
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Default Re: Can't Remove Spark Plug

The spark plug socket supplied with the 400 has a thinner twall han a regular spark plug socket that you get with a socket set.
Has anyone used these rather than the one supplied without difficulty in get it in or is it too
thick to fit around the plug?
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Old 04-19-2009, 12:10 PM   #5 (permalink)
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Default Re: Can't Remove Spark Plug

I used a regular spark plug socket set. When I replaced the plug and pulled the socket the rubber thingee stayed behind and I used some needlenose pliers to pull it out. You can always remove the rubber thingee before re-installing the plug to avoid this issue. I had no issue with the thickness of the socket walls. If you use the spark plug tool that comes with the bike you can't use a torque wrench so you have to guess-ti-torque by hand.
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Old 04-19-2009, 12:45 PM   #6 (permalink)
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Default Re: Can't Remove Spark Plug

Polyian, you state that you just pulled it out......I'm puzzled as to what the purpose
of this sleeve is. There has to be a reason for it and yet I've never seen it on
any engine, car , truck or otherwsie

In reading in the "How To" no one has ever mentioned that they experienced this problem so I suspect that this rubber was not in thiers?????? puzzled
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Old 04-19-2009, 01:18 PM   #7 (permalink)
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Default Re: Can't Remove Spark Plug

The rubber insert was in the tool that came with my bike. As for the purpose of it it's just a grip for the end of the plug so when you get the plug loosened from the head you can just remove the tool and the plug stays in the end, no fishing it out with pliers. Though putting the plug back in I can see problems with the rubber part staying on the plug certainly.
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Old 04-19-2009, 01:21 PM   #8 (permalink)
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Default Re: Can't Remove Spark Plug

The rubber insert is part of the spark plug socket and when you yanked the socket up the rubber stayed behind with the plug. This is common and the reason many people pull the rubber out of the socket before re-installing the plug. It is handy to have there when removing the plug. It's purpose is to help prevent damage to the porcelain on the plug. In the old days we never had these rubber inserts and I neve broke a plug.
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Old 04-19-2009, 10:36 PM   #9 (permalink)
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Default Re: Can't Remove Spark Plug

I've never had this problem.... The rubber boot holds the socket in place as you snake it down the long tube to get to socket to screw it in and helps ensure it stays straight to help prevent crossthreading. And mine has always stayed in place, whether it be the one that came with the bike, or the set I used for my car.

Just got to not ''yank'' out the socket when you remove the plug.
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Old 04-20-2009, 01:00 PM   #10 (permalink)
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Default Re: Can't Remove Spark Plug

Thanks for all the fine advise and I attacked it again yesterday and had to fish this
rubber washer out with a piece of bicylce spoke that I filed sharp & bent to a hook-
shape and finally was able to get at the plug with no problems. This thing was so embedded around the plug base that it broke up and I pulled it out in several pieces. Never have I had a
problem with a spark plug socket that comes with a socket set.
That tells you what a piece of garbage Suzuki supplied and had I known of this before
inserting the tool for the first time, I would have never used it.
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