Question about 2005 KTM 625 SMC

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How do you remove the spark plug cap. I have applied a little pressure but I dont want to damage anything.

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  • KTM Master
  • 1,554 Answers

IF you mean the metal barrel that threads onto the end of the plug:
Remove spark plug, hold by the hex with a wrench, and grab the barrel with a pair of pliers and unscrew.

Posted on May 12, 2014

Testimonial: "On the KTM its not a metal barrel its plastic and has the NGK stamp and is attached to the plug wire."

  • Strech
    Strech May 12, 2014

    Ok, you mean the sparkpug boot. Grab it and twist it back and forth a few times to break it loose, then pull while twisting.

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There are several problems that can cause this behavior, Is it cold where you are? If so the geo's have a known issue with starting in cold weather.

If not then here is a list of possible issues

1.) Cracked or damaged ignition coil and/or primary wire.
2.) Fuel Pump.
3.) Clogged fuel injectors (Engine will run rough when it does run if this is the case)
4.) Badly worn spark plugs, Spark Plug wires, Distributor cap and/or rotor.

*** WARNING *** Your ignition system contains dangerous voltage levels that could seriously injure or kill anyone coming into contact with the spark. Be sure to use insulated pliers or a spark tester and follow the instructions. Failure to do so could cause serious injury or death.

Tests to confirm:
1.) Purchase a spark tester from your local auto parts store, Connect a spark plug wire to the tester and connect the tester as described in its documentation, Have a friend crank your engine and watch for a bright blue spark, The spark should happen frequently and with a rythm, If it seems to skip alot proceed to test #4. If you dont see a spark at all the ignition coil is to blame, Even if you do see a spark, It should be bright blue and clearly visible in daylight, If it is then your ignition coil is doing its job.

2.) Get a pressure gague and hook it up to the fuel line, Turn the key off and on several times (Dont start the engine) if the pressure doesn't rise when the key is turned to on, Your fuel pump may be faulty, Even if it does rise it should reach 15 PSI, If it doesnt then replace the fuel pump and fuel pressure regulator.
3.) You would have to remove the injectors. I recommend you have a mechanic check to see if this is the problem.
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The solution is:

Engine cover removal: Fairly simple, I will try to explain this best I can without pictures. To start, you will want to remove the connecting air intake hoses (BIG tube looking thing on bottom right of the top of the engine) it is clamped down, just take some pliers and unclamp it to remove hose. Then the hose right next to that one (adjacent to the front bumber) You will need an star screw driver, if you look at the two screw's heads on either side of it you will know what i'm talking about. Then that comes off. Then there is a wire attached to the air intake hose, you must unconnect it, (I explained already how to take wires off in the spark plug section below, they are all the same) Next all you have to do is pull up on one side of the engine cover. (if you look at the back left of the cover you see what looks like a rubber gromet, kinda of look like you need to take that bolt off just to get anywhere.. you don't, that rubber peice acts as a snap on button say on your shirt perhaps) You pull hard enough it will come up, and there is four of those rubber gromet fasteners so just keep wiggling it and pulling until you get it off.

Spark Plug removal:

The spark plugs are located on the very top in plain sight of the engine, easy easy to get to.. you will see (not the actual spark plug just sitting there staring at you, they are under the caps) There are five caps all facing the same way and they have wire connections hooking to all of them. First you have to unconnect the wire to the cap. Take a skinny flat head screw driver.. and stick it in the middle of the wire housing (don't get confused, the housing is just the plastic piece that is black, it "houses" all the wires that power the spark plugs) The middle of the wire housing you will see a little perfect sqaure opening, there is a little clamp thing in there and with the screw driver all you do is put pressure upward (toward the back of your car) and pull at the same time and the housing will disconnect from the spark plug cap. Do this to all five caps.

Next the cap itself, is really easy to take out, just use that same flat head screw driver to kind of pry underneath the cap, don't be afraid to put pressure you won't break anything, Then the cap will come off and underneath the cap (attached to it) is the spark plug covers (acts like.. a battery in the remote) long metal tubular looking things.. if you see that, your doing good. Now look down into the whole you just removed the spark plug cover from, you will see the top of the spark plug down in there. Do this for all five caps.

Now you need tools, a medium size wratchet would do good. make sure you have a loong extension, and a deep well (long) socket (size in MM is 15 in standard 9/16 or one higher) loosen (lefty loosey, righty tighty) the spark plug until you can pull it out with the wratchet.. discard old, put in new spark plug, tighten but not tight tight.. do that for all five spark plugs.. once new spark plug is in, put the spark plug cover and cap combo back into the whole ( MAKE SURE YOU CLEAN IT AND THE WHOLE OUT BEFORE HAND) then just apply little pressure and the cap will set back into place (just make sure it is facing the way it was before) then connect the wiring back to the end of the cap (just slide it on and push it will "click" into place) do that for all .. then put your engine cover back on, reconnect the hoses and the wire on top of the hose. You are then good to go.

Oct 17, 2008 | 2006 Volkswagen Jetta

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