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Broken Spark Plugs Remedy? 10 Dec 2021 16:16 #858928

  • Dr. Frankenstein
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Well, it happened Again; I was hoping it wouldn't but it did. This bike has been outside for a looong time, and when I went to take out the spark plugs what I thought was a turning turned into a Crunch..! 

Yes, BOTH spark plugs turned all right; that little silver ring is what remains of the spark plug threads; on both sides! If you look closely you can see the remains of the spark plug tip in the cylinder.  It appears I have some work ahead of me.  Any ideas for getting those out?  I had soaked them in PB Blaster for a week and tried to use heat before I attempted to turn them, but they broke faster than Betty White's hip. It didn't take much.
Because of this I've back-burnered the KZ400 project until I can drop the engine and take it all apart, but I'm hoping somebody here has a solution...? 
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Broken Spark Plugs Remedy? 10 Dec 2021 17:00 #858929

  • ghostdive
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I'd try a fluted screw extractor; I struggled with a broken plug like this in a variety of other ways and none of them went anywhere - least of all a spiral-type extractor. If that doesn't work, I'd pull the head, I think that's the path of least risk of damage. 

 
1982 KZ750 Spectre - 6 speed swap, 4-1, BS34s, 18" rear wheel

2001 ZX-6R
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Broken Spark Plugs Remedy? 10 Dec 2021 19:19 #858933

  • Dr. Frankenstein
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Actually, I came upon this - a pipe nipple extractor from Lowes, $11 - Harbor Freight has one too, but this one seems a bit better:
Kobalt Pipe Nipple Extractor Set in the Plumbing Wrenches & Specialty Tools department at Lowes.com

I will of course report back when it happens.

 

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Broken Spark Plugs Remedy? 10 Dec 2021 22:14 #858938

  • F64
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Check out Autozone's free loaner tool for a Ford Triton spark plug extractor.
It may work, but double check the clearances as the spark plug is a different size externally.
Ford trucks had a fun time breaking spark plugs so there was a tool created.

www.autozone.com/nuts-bolts-and-washers/...mover-set/409619_0_0

 
81-KZ440-D2.
Louis Dudzik's GM HEI ignitor conversion installed 2015 s3.amazonaws.com/gpzweb/Ignition/GPZgmHEImod.html
Motogadget m-unit blue installed 2017.
LIC, NY
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Broken Spark Plugs Remedy? 11 Dec 2021 21:40 #858971

  • noman
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of course i'd check the work done before install, but there's a refurbished replacement head (p/n 11002-1003) on ebay at the moment for $99/shipped.    
i also have a spare head for a 79, in nice shape and less expensive.   
79 kz400
66 S65

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Broken Spark Plugs Remedy? 11 Dec 2021 22:02 #858972

  • Mc Tavish
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Ha, yeah. that was a PITA. Most F150's over here spat the plugs out all by themselves, no tool required! 
1978 z650C

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Broken Spark Plugs Remedy? 12 Dec 2021 06:29 #858978

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I've always used anti-sieze on mine and they've always came out like butter.

Some don't some do from what I've read on here but this is one thing I probably won't be talk out of.
1978 KZ650 b-2
700cc Wiseco kit 10 to 1.
1980 KZ750 cam, ape springs, stock clutch/ Barnett springs.
Vance and Hines Header w/ comp baffle and Ape pods, Dyna S and green coils, copper wires.
29MM smooth bores W/ 17.5 pilots, 0-6s and 117.5 main
16/42 gearing X ring chain and alum rear JT sprocket.
The following user(s) said Thank You: slmjim+Z1BEBE

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Broken Spark Plugs Remedy? 12 Dec 2021 14:15 #858986

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I've always used anti-sieze on mine and they've always came out like butter.

Some don't some do from what I've read on here but this is one thing I probably won't be talk out of.

+1

We've used Bostik Never-Seeze Standard Grade on plug and other threads for decades.  Almost always on steel fasteners threading into aluminum.  Just have to be very careful not to over-torque, as can easily be done on lubed threads.

Good Ridin'
​​​​​​​slmjim & Z1BEBE
A biker looks at your engine and chrome.
A Rider looks at your odometer and tags.

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1974 Z1-A x2
1975 Z1-B x2
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Broken Spark Plugs Remedy? 12 Dec 2021 19:02 #858989

  • blipco
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Applying heat may help with the extraction. A magnet should get the tip out of the cylinder then suction out the porcelain.
"Swim against the current, even a dead fish can go with the flow"-somebody (I forget Who)

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Broken Spark Plugs Remedy? 13 Dec 2021 09:45 #858998

  • Dr. Frankenstein
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Update - I tried the pipe nipple removers, but no luck there; after doing some more reading I've ordered some square fluted screw extractors to see if that makes a difference. What really bugs me though is I managed to break off two cooling fins with the breaker bar!  

Noman, PM me about the head please; thanks!

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Broken Spark Plugs Remedy? 13 Dec 2021 13:13 #859005

  • z1kzonly
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Drill out most of it! 
EDM burn it out!
Research EDM ( electrical discharge machining)
Any and all of those e z out extractors are just going to push outward against the thread, binding it more.
Drill it out. put an insert back in!
I had a plug broke off in a 79-80 smog KZ1000 head. It sat for 20 years! it was not going anywhere! I drilled down to the minimum, the just chisled the thin metal out that was left. Got lucky to just run a nice sharp 14mm tap through. Not a plug chaser. It looks ugly, but with 3/4" of threads! A new plug will work fine.
At least I hope so when I sell the 12,000 mile head, all fresh and rebuilt on eBay! 
This was one of my KZE1-E2 shafty's I bought to part out. Virgin low mile MarkII case and crank sold for $500 to the drag racers. I paid $200 for this whole bike!
The seller was the one who chisled up the opening. How do you spell (chisled??) 
Livin in "CheektaVegas, NY
Still have a Kaw! 76 KZ900 Pro-Street.
Went thru 25 of these in 40 yrs.

And The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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Broken Spark Plugs Remedy? 13 Dec 2021 15:08 #859018

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Did you try heat?
"Swim against the current, even a dead fish can go with the flow"-somebody (I forget Who)

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