Quest to Remouve the Broken Spark Plug

Well this has been a bit of an interesting start for getting this bike running again. The bike hasn't been started in potentially 20 years, so I was going to fill the engine with diesel for a week and let it break up anything in there. However, one of the spark plugs didn't like that idea, and snapped off.

I managed to suck the porcelain out with the shop vac, but the rest of the plug is still stuck in there. I got out the good old screw extractor bit set and some DW-40. I periodically sprayed the plug with DW-40 for 3 days before trying to extract the thing. Taped in the extractor and attached the tap wrench. BOOM!! Tap wrench exploded.

Someone told me that you can use a 10mm socket on the end of the extractor, so this time, I tried heating the plug, letting it cool, heating, cooling, heating, cooling, then heating and trying with the 10mm socket. Well that wasn't a good idea. Tore out the teeth in the socket.

I really didn't want to drill this thing and get shavings in the cylinder. So I went looking through the tools here and I found an old metal punch that would work. I hammered the punch into the grooves that the screw extractor made. Got it in there real good, then put a 5/16 socket on the end of the punch that fit tight. Got out the breaker bar and my slip on extender for leverage. Well I thought I had it turning a bit, but then I realized I was wrong. I actually twisted the punch.

I have no idea why it is stuck in there, but I'm starting to wonder if it got welded in there somehow. Metal shavings went down into it this time though, I know that for sure so I guess the head is going to have to come off anyway. Any ideas or tips for getting this thing out?

 

I use a long socket bit to get mine off. You might be able to rent something suitable from autoparts store for cheap.

 

Uhhhhhhhh......

 

Any chance of :

1. drilling into it, then
2. screwing a bolt into the drilled hole
3. welding the bolt to the plug body
4. let it cool completely
5. use a six-point socket and ratchet on the bolt

?

 

I like the idea, Guy, but that is a lot of heat that close to the head.

 

No, it broke off slightly inside the head, so it wouldn't have any room to get the welder in there. I think i am going to have to drill it out carefully. The metal for the plug seems relatively soft, so If I drill it thin enough without touching the threads, I might be able to bend it and collapse it on itself and pull it out.

It takes careful doing, but I have managed to do it on a bolt before. Unfortunately this will require me to remove the head to clean it out properly afterward, and I won't likely have money to buy a new gasket until next month. Speaking of that, does anyone know a good place to buy a gasket kit? The bike is a 1984 Maxim 400. It is the same as the 1983 as a lot of places don't list the 84 since they didn't sell in the US.

 

The Chemical action which has SEIZED that Spark Plug into the Head is GALVANIC SEIZURE!
Old-timers call it: Cold Welded.

A Chemical Reaction has BONDED the two.
So badly the resultant bonding is stronger than Tool Steel.

The Fragment needs to be BURNED OUT in a Process known as Disintegration Machining.
Electrical - Discharge - Machining.
EDM for short.

http://www.edmmachining.com/

The Fragment is exposed to an Electrical Arc which is highly controlled.
A WIRE Filament creates the Arc and the Steel Fragment totally disintegrated.

Take-off the Head!
Just look-in and see what condition your condition is in.

 

I gotta ask tiger, you didn't by chance follow the instructions on the package of the easy out?

 

Well since I can put the diesel in through where the porcelain was, I think I may do that and leave it for a week. At least then when I take the head off, I may have a better chance of something else not being ceased inside. It should be ready for me to take apart then when I get back from my trip I am taking in a few days.

 

Get a left handed drill bit from a machine shop, it will probably unscrew as you are drilling.

 

If there is no steel in the head that you don't mind dissolving, alum might work for you. Watchmakers use it to dissolve steel screws broken off in brass movement plates. I checked, and apparently it's OK on aluminum as well.

http://www.craftkb.com/Uwe/Forum.aspx/m ... experiment

 

Kroil

 

I would pull the head and head for the machine shop. Cheaper than messing up your head and having to replace it as well. If the shop wants more than an hour for the fix, find another shop.

 

Yeah, I'll probably end up taking the head off next week. Let's hope that the bolts will come free nicely.

 

Let me know how you make out. I have the exact same problem right now with a parts bike (XJ550) I picked up. 3 of the 4 plugs came out fine but the #2 cylinder plug snapped right off
Low mileage bike but sitting a long time outdoors. Was considering reverse drill bit but don't want to damage threads. Also worried about head bolts if/when I need to remove head.

 

the thread is 3 years old and the op hasn't been back since. my guess is that he abandoned the bike all together. but do let us know how you make out. does that parts bike engine turn over? if not, number two is likely seized and the whole thing is just nuts bolts and washers.

CN

 

Thanks for the reply CN- didn't notice the thread age; I was searching for solutions that worked for others and this thread came up in the search results. The good news is the engine is not seized and the crank does turn; the bad news is there are now 3 hurdles to getting this engine running 1) broken #2 spark plug 2) seized clutch 3) seized and now damaged carburetor idle mixture screw (ironically also on #2 cylinder). Engine has less than 10k miles; wanted to just get it running to ensure all important parts worked (ignition, fuel system, electrics, etc.) then decide what to keep and what to sell from this untitled bike. Was hoping engine and carbs could be a good backup for my current runner that has 50k (mostly city) miles.

I'll let everyone know if I make any breakthroughs on those three hurdles.....and share any tips for others with similar issues.

 

Pull the head off and remove the spark plug from underneath. If it was sitting outside for so long, and has no title, don't fret about tearing the engine down a little bit. Probably make more $$$ selling it piece by piece, anyway.

 

Good advice, but its cold in my unheated garage with limited space to work with all 4 bikes in there, so tearing down is not really an option until spring. I was hoping to just get it running by Xmas (the only time I have time) to give me an indication of viable parts options and spares for my running bike, which is getting high in mileage. With my luck, any part I take off and sell now will be the first one to fail on my runner....lol

 

Heads are cheap on ebay, I got one with nice cams for $35, no broken fins or anything.