Broken Spark Plugs Remedy?

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10 Dec 2021 16:16 - 10 Dec 2021 16:21 #858928 by Dr. Frankenstein
Broken Spark Plugs Remedy? was created by Dr. Frankenstein
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...? 
  • Last edit: 10 Dec 2021 16:21 by Dr. Frankenstein.

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    10 Dec 2021 17:00 #858929 by ghostdive
    Replied by ghostdive on topic Broken Spark Plugs Remedy?
    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, BS34s, 18" rear wheel

    2001 ZX-6R
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    10 Dec 2021 19:19 #858933 by Dr. Frankenstein
    Replied by Dr. Frankenstein on topic Broken Spark Plugs Remedy?
    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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    10 Dec 2021 22:14 - 10 Dec 2021 22:17 #858938 by F64
    Replied by F64 on topic Broken Spark Plugs Remedy?
    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.
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  • Last edit: 10 Dec 2021 22:17 by F64.

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    11 Dec 2021 21:40 - 11 Dec 2021 21:46 #858971 by noman
    Replied by noman on topic Broken Spark Plugs Remedy?
    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
    Last edit: 11 Dec 2021 21:46 by noman.

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    11 Dec 2021 22:02 #858972 by Mc Tavish
    Replied by Mc Tavish on topic Broken Spark Plugs Remedy?
    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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    12 Dec 2021 06:29 #858978 by KZB2 650
    Replied by KZB2 650 on topic Broken Spark Plugs Remedy?
    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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    12 Dec 2021 14:15 #858986 by slmjim+Z1BEBE
    Replied by slmjim+Z1BEBE on topic Broken Spark Plugs Remedy?

    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.
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    1973 ('72 builds) Z1 x2
    1974 Z1-A x2
    1975 Z1-B x2
    1993 CB 750 Nighthawk x2
    2009 ST1300A

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    12 Dec 2021 19:02 #858989 by blipco
    Replied by blipco on topic Broken Spark Plugs Remedy?
    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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    13 Dec 2021 09:45 #858998 by Dr. Frankenstein
    Replied by Dr. Frankenstein on topic Broken Spark Plugs Remedy?
    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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    13 Dec 2021 13:13 - 13 Dec 2021 13:14 #859005 by z1kzonly
    Replied by z1kzonly on topic Broken Spark Plugs Remedy?
    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
    Went thru 25 of these in 40 yrs.
    I SOLD OUT! THE KAW BARN IS EMPTY.
    More room for The Old Girl, Harley 75 FLH Electra Glide,
    Old faithful! Points ign. Bendix Orig. carb.
    Starts everytime!

  • Last edit: 13 Dec 2021 13:14 by z1kzonly.

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    13 Dec 2021 15:08 #859018 by blipco
    Replied by blipco on topic Broken Spark Plugs Remedy?
    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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