Broken Spark plug

[kawasutra]

Got 3 out and replaced and the last one just snapped with the first attempt at turning the wrench to get it moving. Gutted!


Anyone broken it a similar way and managed to get it out without going the long route?


[smg id=2676 type=preview align=center caption="IMG 20151010 141436"]

[Paulfzs]

iridium sparkplugs


they last forever!
last years before they need to be removed...


then this happens.


cant you get anything inside it and turn it?

[kawasutra]

Hehe! I bought normal NGKs off ebay to replace whatever last owner had put in.




I want to remove the front fairing inside panel to get straight line access into the recess before attempting anything.

Also, saw a post in this forum about using a torx bit but the pic isn't there so can't see if it was a similar break to mine.


I need advice but perhaps a pic of what remains in the recess would be useful.

iridium sparkplugs


they last forever!
last years before they need to be removed...


then this happens.


cant you get anything inside it and turn it?

[Paulfzs]

ive not seen inside a broken spark plug but if it has a hole in it, get a torx bit of around the same size but a little bigger and hammer (gently) it into the hole and then unscrew it.


Torx bits are pretty good for most damaged screws and such because it has many edges to grip with.

[kawasutra]

This is the thread: http://foc-u.co.uk/index.php/topic,1160....ml#msg7847


I will remove inside panel in the morning and report back, but torx bit idea most promising at the moment.


Cheers!

[Paulfzs]

yeah same as i said pretty much.


dont hit it hard itll destroy the thread

[Val]

This is the thread: http://foc-u.co.uk/index.php/topic,1160....ml#msg7847


I will remove inside panel in the morning and report back, but torx bit idea most promising at the moment.


Cheers!

I would try torx. Probably good idea to use WD40 or penetration fluid before that.

I have used torx twice so far for stuck bolts. One time was radiator 4mm Allen bolt chemically bound and stuck. I've used T25 which is 4.43mm and a hammer. Soaked it with penetration fluid. Embedded the torx well and than just slight tughtening to break it and than slight untighten. Than again slight tighten and again untighten. It broke well. Than just unscrew.

Measure the hole and See Torx sizes:

https://en.wikipedia.org/wiki/Torx#Sizing

[Bretty]

When the plug snaps like that I think it leaves the threaded part in the engine with it's ceramic core. Be carefull when whacking anything down the middle of the plug that you don't push that bit of ceramic into the engine.
I've heard people suggest that if you turn the engine over the pressure should blow that ceramic core out.

If you can get that ceramic bit out of the middle, I would be tempted to attack it with a torx bit in an impact driver with lots of penetrating fluid or get an easy-out on it.

Either way give it a good soaking in penetrating fluid as your plug looks well corroded.

Alternatively if you take the head off (a bit more of a ball ache than it sounds) you'll be able to unscrew the plug from the other side with some long nose pliers.

If you ever do get the old bit of plug out, don't forget the spark plug washer which might still be in the top of your engine! 

[kawasutra]

It's a pretty hard to reach recess for the plug.


My plan is to order some easy outs from screwfix, a long thin drill bit and a lot of penetrating oil.


Soak in oil for  24 hours and then try to drill a pilot hole in the middle of the remaining plug, then get the easy out onto it.


The little metal washer came off with the broken bit, but am still weary of getting anything into the cylinder.


Not an advanced bike-tinkerer so doing a lot of reading and you tube viewing before going for it.

[Paulfzs]

hex bit extension bar is all you need to reach in there.


http://www.ebay.co.uk/itm/QUICK-RELEASE-...463e071a86

[kawasutra]

This is how it looks. So there is no hole to get a torx into and turn. Pilot hole and then easy out extractor?


[smg id=2678 type=preview align=center caption="plug hole1"]

[davey boy]

I hate easy outs never once got them to work as they expand the bolt they are extracting which you don't want to do and a guy at work snapped one in the same situation you are in and then you can't drill the hardened easyout then it was a head off job
I would try the torx method if I where you

[Paulfzs]

Oh i see! i thought it was hollow inside!


drill a pilot hole and try a torx bit, if it fails try easy out.


plenty of penetrating fluid (not wd40) and a little heat may help.


Banging the torx bit in may loosen the seal a little which will help.

[sinto607276]

I'm not sure of what the inside of a spark plug is like tbh but as you've got one out already, why don't you cut across it and try drilling that in a vice etc first before you try and drill the one out in situ?

You may be able to drill small pilot holes as suggested already but try and do a couple or three in a row and get a screw driver into it and unscrew it that way?

[Bretty]

You won't drill through the middle of the spark plug! It has a ceramic core. Harder than any drill bit. With a very small metal part going through the middle of that

You'll drill through the metal, but as soon as you hit the ceramic the drill will just spin in the hole.

[Bretty]

http://www.fordanglia105eownersclub.co.u...plug02.jpg

[maniaka]

Hey dude sorry this has happened to you - a real ball ache.


Same thing happened to me !


I used a ceramic drill to drill out as much of the spark plug as I need to allow an easy out to grip the metal thread.
Soaked with penetrating spray overnight and a few other occasions.


Then I used an easy-out. it worked but was lucky, non of the garages wanted to touch it without taking the head off and drilling it out.


Tip 1) Pre drill it, otherwise you will struggle to get it to bite however only drill what you need - don't want swarf in the cylinder
Tip 2) Go slowly when using the easy out - they blunt real quick and you only get a couple of shots.


Worst case scenario ... you dont drill enough and you snap the easy out as you turn it too fast !


But it is possible to get out .. heres mine using a halford easy out [second to largest size from memory]

[Bretty]

Good effort getting that out!

Your photo shows the ceramic core only just held in place by the electrode.
That's the bit you need to be careful doesn't drop into the engine, when you drill or insert the easy-out.

[kawasutra]

hex bit extension bar is all you need to reach in there.


http://www.ebay.co.uk/itm/QUICK-RELEASE-...463e071a86

Paul, do I need this to drill a pilot hole? I'm assuming that it's needed to get past the frame and into the recess.

[kawasutra]

I'm not sure of what the inside of a spark plug is like tbh but as you've got one out already, why don't you cut across it and try drilling that in a vice etc first before you try and drill the one out in situ?

You may be able to drill small pilot holes as suggested already but try and do a couple or three in a row and get a screw driver into it and unscrew it that way?

I thought of this idea but do not have a work bench or a vice at hand. I will see if my neighbour is willing to let me try this on his vice.