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PAIR System Removal and Spark Plug Replacement Tips

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12K views 27 replies 16 participants last post by  g00gl3it  
#1 ·
I removed the PAIR system on my '02 919 today, installed semi-gray's block off plates and replaced the spark plugs while I was at it. Ken's excellent directions helped me through it with no problems, thought I'd post a few of my own pictures, along with some lessons learned that made it easier for me.

Entire project took about 2 hours from start to finish, taking my time and proceeding carefully. Probably could do it again in 30 minutes now that I learned a few tricks.

I'm very pleased with the final result, totally eliminated the popping and backfiring on decel, seems to have smoothed out some jerkiness at low speed constant rpm's as well. The new plugs make for an easier start up, not that it started hard before, but just fires instantly now. Also idles more smoothly, none of the loping that I experienced before.

Hope this helps someone else. I highly recommend getting rid of the PAIR system and installing semi-gray's blockoff plates, which by the way, are perfectly machined and fit like Honda made them.


Started out with Ken's directions: http://www.wristtwisters.com/forum/showthread.php?t=5438&highlight=pair+removal


I found it easier for both the PAIR removal and spark plug replacement to unbolt the 1-4 coil and move it out of the way

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I also figured out that if I removed the screw holding the water hose junction in place, I could move the hoses out of the way and make the right side PAIR removal and 3-4 plug replacement much easier

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Left block off plate installed

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Right block off plate installed

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Taped off electrical connector for PAIR valve

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Found the perfect trim plug to close off the hose nipple at the airbox, a bit of electrical tape around the nipple and the plug was a perfect fit

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PAIR system parts removed

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#3 spark plug is a bitch! Flexible extension, combined with two short extensions managed to get the job done. Quite the trick to pull the plug up out of the hole though, as my extension was too long to come out attached to the plug socket without hitting the frame, took some major finger dexterity to solve that one!

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Original spark plugs @ 7290 miles. Still looked pretty good

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But the precious metal ones will be better!

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Almost ready for reassembly

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Left side completed

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Right side completed

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#2 ·
Excellent write up. Some good tips in there too. You also make a great finger model by the way :) Tell us if you notice any difference in those new plugs!
 
#3 ·
+1 on the block off plates and plugs. Before I installed the block off plates I didn't think silencing the back fire would be that noticble but I was wrong. It sounds better and changing the plugs are deffinetly a lot easier now.
 
#4 ·
Looks like you might have an oil leak around your valve cover gasket into a spark plug hole or two. If the plugs are in the order you took them out.. #2 or #3. Maybe it's just an optical illusion there in the picture?
 
#6 ·
I noticed that bit of oil on a couple of the plugs, although there was no oil visible in the holes when I pulled the plugs out. Of course it's virtually impossible to see completely down into the holes and I didn't have a mirror available. Is that common for the vc gskt on the 919 to leak like that? I know some import cars from my service director days, specifically Mazda 2.5L V6 engines, were notorious for filling up the plug holes with oil, eventually leading to bad plug wires and shorting out the distributor.
 
#8 ·
sbeau1960 said:
I highly recommend getting rid of the PAIR system and installing semi-gray's blockoff plates, which by the way, are perfectly machined and fit like Honda made them.
Click to expand...
Aww Shucks :blush: Thanks!
I'm really glad these are so well received. I originally made them for easy valve cover removal for the 16k checkup, but they really do have a positive effect on the exhaust note.

sbeau1960 said:
#3 spark plug is a bitch! Flexible extension, combined with two short extensions managed to get the job done. Quite the trick to pull the plug up out of the hole though, as my extension was too long to come out attached to the plug socket without hitting the frame, took some major finger dexterity to solve that one!
Click to expand...
Try a magnet!
 
U
#9 ·
I am tempted to try this mod myself. My 919 has gotten to 10 000 very hard KM's (city and dirt riding by a 270 pound rider who flogs it) and now is ready for some serious maintenance. I may try the flappervalve mod as well.
 
#13 ·
Flapper mod is very easy and it certainly can't hurt. I can't say I noticed any major difference, but common sense says lots of air is always better than a little bit of air sometimes.
 
S
#14 ·
I also removed the PAIR today...haven't felt any significant difference yet.
After finishing this, I asked myself: why didn't I just block the air suction hose and the airbox nipple?? that should have the same results right? But of course .. having those unused parts removed, the interior looks cleaner ..
 
#15 ·
Although I have not changed plugs on a 919 yet, I have on other bikes and my Tacoma and Camry...One of the tips I like is to use a 8" to 12" piece of clear tubing, 1/4" or 3"8"...I can't remember now, either should work.

Simply loosen the plug about 3/4 of the way, push the tubing onto the plug, unscrew and lift out. Also works great for reinstallation...put the plug onto the tubing and place it into the abyss...greatly reduces any chance of for cross threading as you can really feel what is going on.

Hope this helps.
 
#24 ·
Wow that bike looks mean. There is a KTM dealer down the street from my work and I asked about a superduke and he said he didn't even think he could get one.
 
#26 ·
They were last imported to the US in 2008, I bought mine new off the showroom floor in 2010. The new Super Duke 1290 will be here soon, it promises to be even more bad ass, if that's somehow possible!

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