Broken spark Plug

Hey Guys,
Ran into a small glitch. I was trying to get a plug out and it broke off. Only the thread part stayed in the head. The ceramic and spark came out. How the hell do I get that out???
:dry:

Or do I just have to buy a new head? This is a 1976 KZ900 LTD BTW.

Thanks
Fratedog

Back in the old days, they made a product called "Easy out" and I recall you drilled out the center of the stuck part and there was a reverse threaded insert thing you screwed into it. When tight, it allowed you to unscrew the broken off piece.

in the us they are called easy out in uk there called bolt extractors.
anyway this is what they look like i have a set and there worth getting just in case.

Thanks Guys,
I am know about the extractors. Problem is the plug was stuck HARD and I could not get enough torque with the wrench
I soaked it in WD-40 for a day and then used a pipe to extend the handle of the wrench. That is when it broke. Do you think the extractor will still work?

Thanks
Fratedog

I was thinking that when I read your post. Do you remember installing that plug? How long has it been? Either it's cross threaded or siezed in head. If it's that tight, an easy out may not work. I've had similer situations where I've drilled out a broken bolt in steps till it had a very thin wall and then carefully pried that away from the threads. Problem here is removing hard steel from soft aluminum threads. Unfortunatly I would say the head needs to come off for repair. After repair, use anti sieze on plug threads.

You may have to pull the head.
But first;
Soak the plug with a quality solvent.
I really like PB Blaster.
It is a much better product than WD40.
Put the extractor into the plug.
Then you need to warm the head.
A heat gun or bottled propane torch works.

CAUTION:

If you are using the open fire route use some common sense. No gas tank or carburetors please!

The heated head will expand slightly and remove some pressure on the plug.
spray it again with solvent and then try the extractor.
Good luck!!

Thanks Guys will try and let you know

Fratedog

theres a product that will dissolve steel, but not hurt aluminum. i think its called allum. make sure the head is off in case you drip any. if that doest work, take it to a machine shop

FloridaBiker wrote:

You may have to pull the head.
But first;
Soak the plug with a quality solvent.
I really like PB Blaster.
It is a much better product than WD40.
Put the extractor into the plug.
Then you need to warm the head.
A heat gun or bottled propane torch works.

CAUTION:

If you are using the open fire route use some common sense. No gas tank or carburetors please!

The heated head will expand slightly and remove some pressure on the plug.
spray it again with solvent and then try the extractor.
Good luck!!

i would say that this is very good advice.may i just add that u should give it a good smack with a hammer to try and shock it loose just before u try to turn it out. seriously. this will actualy help.if it still wont come out u will have to follow bluemeanie's advice and drill it out.

mark1122 wrote:.may i just add that u should give it a good smack with a hammer to try and shock it loose just before u try to turn it out.

That is excellent advice, and I was remiss in not saying so.
Thx mark1122!

I haven't run into this problem yet and hope I never do but what about helicoils. Or at least thats what we call them maybe everyone else knows them by a different name. One of my friends said he had this problem on a chevy V8 and he said he drilled the hole out to the next biggest size threaded it, installed a helicoil and then turned the engine until the exaust valve was open and used compressed air to blow out the shavings. I would think this would work here too except that the chevy uses cast iron heads so that is probably a huge difference. In any case you are better off trying the extractor first.

Bummer ,,,,,,
Everyone is right , it's either seized or crossed in the hole.
I hope it's an outside plug (easier to work on )
I saw some new stuff from a company that I trust ,but have NOT had a chance to try yet .
I know I'm not supposed to use name brands ,,,
but if the moderators will let this by ,,,
The stuff is "CRC FREEZE OFF Super Penetrant"
It uses COLD instead of heat to break the seal between the two metals .

IF you can't get it out , do yourself and your bike a favor and pull the head and take it to a GOOD machine shop and have then put in a "plug thread insert"
good luck