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How to remove a broken spark plug from Cylinder head :(

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  • #1

    How to remove a broken spark plug from Cylinder head :(

    Guys seems like my happy days with RTR is over.
    Everyday she through new challenges for me. The latest one seems more like a disaster then challenge to me.

    A TIGHTLY TUCKED BROKEN SPARK PLUG IN THE CYLINDER HEAD.

    I was having hiccup problems so after checking and cleaning the spark plug while i was putting it back in the cylinder head and when it was almost in, when applied a little force to complete the turns, it started freely moving and when i pulled it ahaaa the spark plug is broken and so I AM.

    Will go to a mech tomorrow and check what could be done.
    Any suggestions.....
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  • #2
    Query approved
    Happiness is finding you have another Gear left....

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    • #3
      Welding a nut on the metallic part of spark-plug. Or removing the cylinder head and then removing the spark plug from inside will have tobe done.

      Comment

      • #4
        Originally posted by flyingJian View Post
        Guys seems like my happy days with RTR is over.
        Everyday she through new challenges for me. The latest one seems more like a disaster then challenge to me.

        A TIGHTLY TUCKED BROKEN SPARK PLUG IN THE CYLINDER HEAD.

        I was having hiccup problems so after checking and cleaning the spark plug while i was putting it back in the cylinder head and when it was almost in, when applied a little force to complete the turns, it started freely moving and when i pulled it ahaaa the spark plug is broken and so I AM.

        Will go to a mech tomorrow and check what could be done.
        Any suggestions.....
        you should use acetylene torch. Heat up the block with it then used a can of compressed air turned upside down to spray the plug and bring the temperature down. Use an easy out, and a pipe around the ratchet.Try this method out,i have read it somewhere so i posted this maybe this can help you out..!!!

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        • #5
          Take it to a competent lathe or follow the below...the best & common method...
          Originally posted by abhichotu.abhi View Post
          Welding a nut on the metallic part of spark-plug
          Skill is what keeps you on a Motorcycle
          Awareness + Skill is what keeps you out of harm's way
          ATGATT + Awareness + Skill means you might Live To Ride another day

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          • #6
            I am hearing this problem for first time and a got a good idea too.

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            • #7
              Originally posted by flyingJian View Post
              Guys seems like my happy days with RTR is over.
              Everyday she through new challenges for me. The latest one seems more like a disaster then challenge to me.

              A TIGHTLY TUCKED BROKEN SPARK PLUG IN THE CYLINDER HEAD.

              I was having hiccup problems so after checking and cleaning the spark plug while i was putting it back in the cylinder head and when it was almost in, when applied a little force to complete the turns, it started freely moving and when i pulled it ahaaa the spark plug is broken and so I AM.

              Will go to a mech tomorrow and check what could be done.
              Any suggestions.....
              is it the porcelain part that broke off or the metal part
              Kawasaki KB100/enduro/125 substitute parts list http://www.xbhp.com/talkies/508615-post105.html

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              • #8
                I think welding or using oxy-acetylene will effect the other components of the engine and will do more harm than benefit.

                Cant we open up the cylinder head and remove the spark plug by twisting/opening the spark plug from inside?
                Speak Less,Speak Wise!

                Sarcasm is my automatic response to stupidity.

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                • #9
                  Originally posted by aargee View Post
                  Take it to a competent lathe or follow the below...the best & common method...
                  Ya exactly, Take your Bike to Lathe , just show them what is the issues,
                  they will take it out easily without any trouble.

                  Don't open up Head , the Lathe work is best and simple

                  Comment

                  • #10
                    Originally posted by theblazerider View Post
                    you should use acetylene torch. Heat up the block with it then used a can of compressed air turned upside down to spray the plug and bring the temperature down. Use an easy out, and a pipe around the ratchet.Try this method out,i have read it somewhere so i posted this maybe this can help you out..!!!
                    this is the proper way for removing the plug without damaging the head... but this requires a lot of skill...

                    alternatively, what most people will do is drill a hole thru the damaged plug (drill dia is slightly smaller than the inner dia of thread so thread does not get damaged). and then remove the rest of the thread easily by tapping with a "1st tapp" for M14.

                    this has ho heating or cooling of engine involved and is hence safer....

                    if nothing works, and if you damage the thread of the engine, you might need to overbore the spark plug, get a bung pressed and re-tapp the thread. (i have never seen this happen yet so cant guarantee the outcome) but getting a new head wll be much better than doing this.

                    hope this helps...
                    Suffering from Parked Motorcycle Syndrome

                    Cant ride ? read this..
                    http://MechMarvels.wordpress.com

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                    • #11
                      Re: How to remove a broken spark plug from Cylinder head

                      Originally posted by flyingJian View Post
                      Guys seems like my happy days with RTR is over.
                      Everyday she through new challenges for me. The latest one seems more like a disaster then challenge to me.

                      A TIGHTLY TUCKED BROKEN SPARK PLUG IN THE CYLINDER HEAD.

                      I was having hiccup problems so after checking and cleaning the spark plug while i was putting it back in the cylinder head and when it was almost in, when applied a little force to complete the turns, it started freely moving and when i pulled it ahaaa the spark plug is broken and so I AM.

                      Will go to a mech tomorrow and check what could be done.
                      Any suggestions.....

                      Interesting

                      Can you please tell us how you or your solved the problem?

                      Comment

                      • #12
                        Re: How to remove a broken spark plug from Cylinder head

                        This had happened with me in past. i was trying to remove the spark plug and it broke , half in my hand, half in the spark plug hole. Bike coudnt start as air passed from the broken spark plug (pulsar has 2 spark plugs so i thought it might start) . took bike to mechanic, he removed the head , then a short trip to the Lathe machine guy. all in all some 200rs expense (60 for lathe machine and rest labout +spark plug)
                        200NS 25K kms / RE500 7k kms / Electra 30k kms / P150 80K Kms(SOLD) / i10 40k Kms (SOLD) / Tata NEXON 2K Kms

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