Spark plug broke off


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alanc1100
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Motorcycle: 1986 GL1200A Aspencade

Spark plug broke off

Postby alanc1100 » Wed Mar 09, 2011 6:23 am



Hi Guys, I got one for you. As I was pulling the plugs to replace my belts, the #3 plug broke right off. From the feel of the other three, they were threaded fine, but the last one I think was stripped when it was put in. That or no anti-seize was used. Anywhoo, anyone know of how to get the threaded portion of the plug out of the head without having to remove the head? Any help would be most awesome.



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WingAdmin
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Re: Spark plug broke off

Postby WingAdmin » Wed Mar 09, 2011 9:49 am

I had the same thing happen to me. I really didn't feel like removing the head, so I soaked it down with PB Blaster for a few hours, then very carefully removed the center of the plug and used an EZ-Out to back it out. Fortunately it came right out with no problem. I used compressed air to blow out the cylinder in case any debris fell into it. It all worked great, and I was able to put a new plug in and go riding.

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starfleetengineer
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Re: Spark plug broke off

Postby starfleetengineer » Wed Mar 09, 2011 9:16 pm

WingAdmin wrote:I had the same thing happen to me. I really didn't feel like removing the head, so I soaked it down with PB Blaster for a few hours, then very carefully removed the center of the plug and used an EZ-Out to back it out. Fortunately it came right out with no problem. I used compressed air to blow out the cylinder in case any debris fell into it. It all worked great, and I was able to put a new plug in and go riding.



This is what I would do. PB Blaster is a wounderful thing ;)
How many times do I have to tell ya,,, The right tool for the right job!

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alanc1100
Posts: 71
Joined: Thu Aug 26, 2010 4:51 am
Location: Lakewood, Wa.
Motorcycle: 1986 GL1200A Aspencade

Re: Spark plug broke off

Postby alanc1100 » Thu Mar 10, 2011 3:37 am

Hi WingAdmin and Starfleetengineer, thanks for the advice. I soaked it or tried to soak it as much as I could with PB Blaster. The easy out ate halfway through the threaded shaft of the plug and it still won't move. Tried it with 1/2" ratchet and extensions as well as a power drill. Neither seems to work. At this point, I have continued to soak it with PB Blaster. Will try again in the morning (I work night shift).

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WingAdmin
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1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: Spark plug broke off

Postby WingAdmin » Thu Mar 10, 2011 3:02 pm

I looked around, and still had the pictures. This is the EZ Out I used, and a small "gator gripper" universal socket I used to grip the EZ Out:



I sheared the top of the plug off using a massive amount of torque trying to remove it, so pulled out the remnants of the plug, then inserted the EZ-Out into the threaded jacket and backed it out - it didn't take much work:



Be careful with the EZ Out - they are extremely hard and brittle. If you break it off, you will NOT be able to drill it out, you'll be taking the head off for sure.

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alanc1100
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Re: Spark plug broke off

Postby alanc1100 » Sun Mar 13, 2011 2:07 am

I bought that tool. It kept grinding but not turning the broke off part of the plug. I tried a spiral easy out and broke it off. So, like you said, now I am pulling the head. So, I bought a used right head for $40. I figure the local machinist would charge me more than that to get the easy out and the spark plug end removed. The things we go through for the love of riding!

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WingAdmin
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Re: Spark plug broke off

Postby WingAdmin » Sun Mar 13, 2011 8:15 pm

Sorry to hear that - I was kind of suspecting that was going to happen. Let us know how you make out!

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alanc1100
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Re: Spark plug broke off

Postby alanc1100 » Wed Mar 23, 2011 11:58 pm

Well, two weeks later and a lot of hours on this job and the replacement head is on. The bike is back together up to the thermostat and housing. Will attack that tomorrow. I installed the new belts per the manual and the crank rotates with no interference in the valves. So, having done this for the first time, I hope my timing is right. New plugs are in WITH Anti-seize on them! I think the reason Honda recommends changing plugs every 4000 miles is due to the steel plug/aluminum cylinder head combination. I have heard from others with different engines that were aluminum that they had to install new plugs a lot more frequently than one would think. I still want to get the radiator pressure/leak checked and maybe buy a new cap. Hopefully, I can find that coolant leak that was coming from the top side of the radiator. Geez, I have been working on this thing since last September. Now that we are starting to see some nice days here in Washington state, I want to ride, man!!!

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alanc1100
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Re: Spark plug broke off

Postby alanc1100 » Sun Mar 27, 2011 3:50 am

Found the coolant leak! The top hose upper clamp was not clamping properly and allowed coolant to leak back onto the radiator. Replaced clamp, no more leak! By the way, I did my own pressure check. The manual gives 7-14 PSI as the operating pressure range for our radiators. I remember hearing about our water system being right around 10 PSI. So, I clamped up the garden hose, closed off the other hose and voila'...the cap released pressure through the overflow with no leakage anywhere on the radiator. Knowing if the cap is releasing at it's proper pressure remains to be seen. Still plan to buy a new cap soon. Just happy to not see any leaks at this point.

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WingAdmin
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Posts: 17045
Joined: Fri Oct 03, 2008 4:16 pm
Location: Strongsville, OH
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1982 GL1100A Aspencade (sold)
1989 PC800 (wife's!)
1998 XV250 Virago (sold)
2007 Aspen Sentry Trailer

Re: Spark plug broke off

Postby WingAdmin » Sun Mar 27, 2011 8:32 pm

Excellent news! Glad to hear of your progress!




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