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P5500 and P6500 Spark Plug Replacement

Required Tools and Supplies

  • Shop Rags
  • Wire Brush
  • Spark Plug Socket
  • Spark Plug Wrench
  • Wire-Type Feeler Gauge

To remove and replace a spark plug on your Polaris P5500 or P6500 generator, follow these steps:

1. Ensure the generator is on a flat, level surface and lock the wheels. If the engine has been running, allow it to cool completely to prevent the risk of burns. 

2. Locate the spark plug on the right side of the generator and remove the spark plug cap. 

3. Using the spark plug wrench supplied in the tool kit, remove the spark plug.

4. Inspect the electrode for wear and carbon buildup. The electrode should have a sharp outer edge with no rounding or erosion. Continue inspecting and replace if the electrodes are worn or if the insulator is cracked, chipped or fouled.

5. Carefully clean the spark plug with a wire brush if reinstalling. 

6. Using a wire-type feeler gauge, measure the spark plug electrode gap. If necessary, correct the gap by carefully bending the side electrode. The spark plug gap should be between 0.028 and 0.031 inches (0.7 – 0.8 mm).

7. Ensure the spark plug sealing washer is in good condition. Thread the spark plug in by hand to prevent cross-threading and then fully torque using the spark plug wrench. A new spark plug should be turned an additional 1/2 a turn after being threaded in by hand, while a used spark plug should be turned an additional 1/8 to 1/4 of a turn. A loose spark plug can overheat and damage the engine, while over-tightening the spark plug can damage the plug threads. 

8. Reinstall the spark plug cap, and ensure it is fully seated.

9. Start the engine using the recommended procedures in your Owner’s Manual to ensure proper operation of the engine. 

For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
More operation and maintenance procedures can be found in your P5500/P6500 Owner's Manual.
For replacement part numbers, use the online parts catalog

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