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Removing Spark Plugs in an Intruder 800

Good Evening from Clear Skies Syracuse.

So, I was able to remove and replace the spark plug from the front cylinder in my (new) 97 Suzuki Intruder 800. It had so much carbon that I could have used it in a barbecue pit (if it weren't snowing).

The problem arose when trying to remove the spark plug from the back cylinder (on the left side of the bike). I was able to remove the lead, although it was surprisingly very tight. The spark plug wouldn't budge.

A big problem is that the opening for the spark plug is underneath the fuel tank, so it was not possible to position the spark plug wrench that came with the bike (I don't know if it is the original). I tried a shorter spark plug wrench but it seemed to be too thick. I placed a rubber element in a regular socket that was thinner and shorter, but the plug just would not budge.

I put the lead back in the spark plug; much, much harder than the operation for the front cylinder maybe because the rubber around the spark plug seemed to be a little bit deformed. I started the bike to make sure that the connected back to the spark plug. The bike started and the engine ran fine and both exhaust pipes seemed to be venting fine, in neutral. The snow keeps coming down; so the bike didn't go anywhere.

I have four questions:

1. The Clymer manual says that if a plug does not move, to put some oil on top and wait 15-20 minutes and try to remove it again. Let's suppose it does not work because the plug is too tight or the space above it is too small. Would the oil affect the spark of the old spark plug?

2. Is the Suzuki 800 one of those bikes that requires the removal of the seat and tank to get the back cylinder's spark plug out? I don't know how difficult an operation that would be (although I assume the air filter will have to be removed soon given the condition of the oil that drained and replaced a few days ago.

3. Is there a very nice, short and thin, 18 mm spark plug wrench in the market that you have been able to use successfully in tight spaces? I may not have the best design for the task.

4. Will the engine suffer from having one clean spark plug and a spark plug that is at least two years old?

Thank you in advance!





1. Try and tighten the plug just very slightly. Then start to back it out. Then tighten it again you may have too do this for the first few threads. If you just start to remove the plug with all the carbon you may just pull the threads out of the head.The reason it is stuck is all the carbon on the threads. Did you put some anti seize on the threads of the new plug? if not do it.
2. It may be easier if you remove the tank, seat and air filter assy. Some times is it just easier to remove stuff than fight working around the pieces.
3. There are several style spark plug sockets. I have 6 and a couple I have modified. I need to remove my tank and seat to get to the 4 plugs on my Stratoliner.
4. It won't suffer much, you will just find that the fuel mileage and performance will suffer. The engine may start to miss and heat up with one old plug that is all carboned up.
I;ll take a look at my VL 800 manual.To refresh my memory..

Thank you, Wayne. I'll go buy some anti-seize and work on the new spark plug tomorrow after work.

The seat and tank... well, it's likely that the air filter has been left in the bike for a long time; so, I'll read up on how to remove the tank, watch a lot of youtube videos, and see if it is something I can do :-).


1. Remove seats 2. Remove fuel tank. 3. Remove plug wires 4. Remove plugs
If you want a air filter, I have a new one for VL 800. Yours if you want it..

Thank you, Wayne! Definitely, I would like the air filter. I will send you a message tonight when I get back home.

squirt some seafoam on it, the residue will just smoke off when its hot

Thank you. I am going to try to remove the seat and the fuel tank this weekend, and then begin to work on that spark plug.

not try.... do.

The removal of the seat and fuel tank was much easier than I feared!

There was an old piece of cylindrical rubber on top of the problem spark plug. I took it out because it was not letting me take a hold of the plug with my spark plug wrench. Once I took that piece of rubber out, it was very easy to remove the spark plug, replace it and put the rubber boot back on. I put anti-seize in both spark plugs before installing them.

I started the bike after putting it all together and it works fine. A pretty sound Smiley-laughing

Thank you so much for your advice! All I have to do now is change the air filter and wait until it warms up in upstate New York... Maybe I should inspect hoses, and change brake and clutch fluids, while waiting for Spring. Winter is not leaving us anytime soon. :-).

Mario you have two air filters a front and rear one. The one I have won't fit as it is for a 2005 VL 800 T. I sent you a message with the part #'s

Hi Wayne.

I just sent you a message.

You were very kind to offer the filter even though it won't fit my bike.

I am going to order the right parts and try to install them. I am getting more comfortable with the mechanics of the bike.

The Intruder is user friendly when fixing and replacing most parts. Except Battery's The more you do your own repairs the more $$$ you will save. The next bike won't be a mystery to you. Glad your getting every thing ready foe this spring. It has arrived here temps in the 50-60"s in the day 30's at night. Nice an sunny with blue skies..

Our high today was 36. It felt warm.

Your warm and mine are miles apart. I'm a candy ass below 40F

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