PAIR System Removal and Spark Plug Replacement Tips - Wrist Twisters
 
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post #1 of 28 Old 07-31-2007, 05:49 PM Thread Starter
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PAIR System Removal and Spark Plug Replacement Tips

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: https://www.wristtwisters.com/forum/s...t=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



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



Left block off plate installed



Right block off plate installed



Taped off electrical connector for PAIR valve



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



PAIR system parts removed



#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!



Original spark plugs @ 7290 miles. Still looked pretty good



But the precious metal ones will be better!



Almost ready for reassembly



Left side completed



Right side completed


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post #2 of 28 Old 07-31-2007, 06:02 PM
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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!

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post #3 of 28 Old 07-31-2007, 09:02 PM
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+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.

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post #4 of 28 Old 07-31-2007, 10:40 PM
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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?

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post #5 of 28 Old 08-01-2007, 04:21 AM
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Very informative. This thread will be added to the Helpful Topics for 919 Owners.

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post #6 of 28 Old 08-01-2007, 05:18 AM Thread Starter
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Quote:
Originally Posted by MotoCycho View Post
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?

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.

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post #7 of 28 Old 08-01-2007, 11:29 AM
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Quote:
Originally Posted by sbeau1960 View Post
... Is that common for the vc gskt on the 919 to leak like that?
Have no idea... I just saw it in your pics. You will have to decide if it's an issue for yourself. Probably can blow it off until you get to 16k miles and need to remove the valve cover to check the vale clearances anyway. I would, your call.

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post #8 of 28 Old 08-01-2007, 05:33 PM
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Quote:
Originally Posted by sbeau1960 View Post
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.
Aww Shucks 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.

Quote:
Originally Posted by sbeau1960 View Post
#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!
Try a magnet!

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post #9 of 28 Old 08-01-2007, 06:29 PM
 
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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.

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post #10 of 28 Old 08-01-2007, 07:15 PM
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Excuse my ignorance, but what is the PAIR system? I assume that it's a breather.

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post #11 of 28 Old 08-01-2007, 07:23 PM
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Never mind I found the old thread.

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post #12 of 28 Old 08-01-2007, 09:58 PM Thread Starter
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Quote:
Originally Posted by semi_gray View Post

Try a magnet!
If only I would have had a magnet, my tools are spread between my work shop and my home garage, did the work in my home garage, and guess where the magnet was?

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post #13 of 28 Old 08-01-2007, 10:00 PM Thread Starter
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Quote:
Originally Posted by Unsub View Post
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.
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.

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post #14 of 28 Old 08-11-2007, 06:40 PM
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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 ..

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post #15 of 28 Old 06-27-2011, 01:22 PM
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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.

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post #16 of 28 Old 04-09-2013, 05:04 PM
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@sbeau1960: do you have a part# for that trim plug? what bike it came off of/location on said bike?

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post #17 of 28 Old 04-09-2013, 05:20 PM
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Quote:
Originally Posted by nandemoto44 View Post
@sbeau1960: do you have a part# for that trim plug? what bike it came off of/location on said bike?
You can go to your local auto parts store and get something like this

One of them will be a perfect fit

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post #18 of 28 Old 04-09-2013, 06:05 PM
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i believe oil on a plug would look shinney black...like tar build up

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post #19 of 28 Old 04-11-2013, 08:24 AM Thread Starter
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Quote:
Originally Posted by nandemoto44 View Post
@sbeau1960: do you have a part# for that trim plug? what bike it came off of/location on said bike?
Wow, I had to go way back into the memory banks to find the answer to that one, not every day one of my 6 year old threads gets revived! I picked up that plug at my local hardware store, it's just a universal plastic plug that was the right size.

Good to see my old 919 is still attracting attention, wonder what happened to the forum member who bought it?

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post #20 of 28 Old 04-11-2013, 08:27 AM
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Quote:
Originally Posted by sbeau1960 View Post
Wow, I had to go way back into the memory banks to find the answer to that one, not every day one of my 6 year old threads gets revived! I picked up that plug at my local hardware store, it's just a universal plastic plug that was the right size.

Good to see my old 919 is still attracting attention, wonder what happened to the forum member who bought it?
I think he contracted carbon fiber poisoning Hey Scott

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post #21 of 28 Old 04-11-2013, 08:30 AM Thread Starter
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Quote:
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I think he contracted carbon fiber poisoning Hey Scott
Hi Mike! Just to show off the long departed old girl one more time to all the newbies, here ya go.....




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post #22 of 28 Old 04-11-2013, 08:52 AM
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Originally Posted by sbeau1960 View Post

Hi Mike! Just to show off the long departed old girl one more time to all the newbies, here ya go.....
You should've kept her. Big mistake.

Spoiler:

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post #23 of 28 Old 04-11-2013, 09:17 AM Thread Starter
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You should've kept her. Big mistake.
Yeah, cuz you know, this sucks...


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post #24 of 28 Old 04-11-2013, 09:27 AM
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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.

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post #25 of 28 Old 04-11-2013, 09:38 AM
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Yeah, cuz you know, this sucks...
True. Very true. I see your point.

Spoiler:

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post #26 of 28 Old 04-11-2013, 09:39 AM Thread Starter
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Quote:
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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.
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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post #27 of 28 Old 04-11-2013, 09:42 AM
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I'm not sure how long my license would last if I owned that. Someone posted a video of that bike on here about a month ago.

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post #28 of 28 Old 04-11-2013, 02:40 PM
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I love those wheels! That thing just has "throw me in jail" written all over it.

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