Z1OwnersClub GB

Morning all. thankfully this is not a prob with my A4. I have a project based on a XS400, but any bike could have this prob.

So, I was removing the spark plugs from the engine, 1 out easy. 2nd not so, despite soaking it for a few days when I was trying to remove it the thing snapped off leaving the threads behind in the hole, ceramic and the core came away. Threads are flush with the head so there's nothing to grip and there's a hole through were the core was. And as it snapped the remaining threads must be pretty well stuck.

So how do we remove the left overs? The head is off the bike and the head is on good condition, covering only 18k miles.

Cheers
Colm

Been there done that

The way I managed to remove it was...

I welded an old knackered tbar to the remains of the plug and whilst it was still hot from welding I managed to get it moving.

If that doesn't work you are looking at drilling and helicoiling

Phil.

You could try an easy-out.....

Compo1955 wrote:You could try an easy-out.....

As it happens I have a set of easy out things. I reckon with plenty of heat could also help.

Don't have access to welding gear and never welded.

bollypne wrote:

Compo1955 wrote:You could try an easy-out.....

As it happens I have a set of easy out things. I reckon with plenty of heat could also help.

Don't have access to welding gear and never welded.

I serviced my mates ford Ka couple of years and one of the plugs snapped like you said !! so i purchased some good quality easy outs ,i used the big one in the set ,and connected a tight fit socket to the easy out, then connected the longest bar i could find to it ,and used all my force to lever it until there was a massive `crack` and it came out !! there was hardly a mark on the easy out ! But i would not try and do this with cheap easy outs , if it snaps of inside of the head then you will be fooked ?
If you need to lend my one ? just p.m me and cover the post ? Andy ...

snotie1965 wrote:

bollypne wrote:

Compo1955 wrote:You could try an easy-out.....

As it happens I have a set of easy out things. I reckon with plenty of heat could also help.

Don't have access to welding gear and never welded.

I serviced my mates ford Ka couple of years and one of the plugs snapped like you said !! so i purchased some good quality easy outs ,i used the big one in the set ,and connected a tight fit socket to the easy out, then connected the longest bar i could find to it ,and used all my force to lever it until there was a massive `crack` and it came out !! there was hardly a mark on the easy out ! But i would not try and do this with cheap easy outs , if it snaps of inside of the head then you will be fooked ?
If you need to lend my one ? just p.m me and cover the post ? Andy ...

Good re cheap Easy Iut things, I've no idea about the quality of those I have. PM on it's way.

In the motor trade they spank a big torx into the remains of the plug then use a big bar on it,trouble is you dont want any bits dropping into the chamber,if you are sure nothing has dropped in this should work,easy outs tend to shatter!

This used to happen to us sometimes.

Get a 1/2 extension and grind the end into a tapered square.
hammer it into the broken plug and remove with breaker bar.
easy outs tend to screw in and tighten. when they snap they are a mare to remove.

If the 1/2 extension snaps you can knock the tapered end out from the combustion chamber side, grind a new taper and try again.

as the head is off the bike another trick.
heat the head in the oven till warmed , pour a little cold water down the inside of the broken plug. then try removing as above

The fact that the head is off is a good start.

I'd dril it out.

IT NEEDS TO BE CENTRED!

Start with a small drill and work up to just under the size of the threads.
You will probably find that as you increase the drill hole the pressure on the threads will reduce enough to allow the remaing portion to be turned.

If however this does not happen, once you get up to the biggest drill, just below the root of the thread, it will come out like a helicoil.

PS I did like the expansion and shrinking idea above.

However the oven will stink FOREVER!!
I've done the oven thing before.
My Fray Bentos steak and kidney pies were never the same again!!

I've had steak and ale pies, steak and beer pies, steak and onion pies, steak and guiness pies. Loved them all.

But steak and EP90 pies are horrible.

jimmock wrote:The fact that the head is off is a good start.

I'd dril it out.

IT NEEDS TO BE CENTRED!

Start with a small drill and work up to just under the size of the threads.
You will probably find that as you increase the drill hole the pressure on the threads will reduce enough to allow the remaing portion to be turned.

If however this does not happen, once you get up to the biggest drill, just below the root of the thread, it will come out like a helicoil.

PS I did like the expansion and shrinking idea above.

However the oven will stink FOREVER!!
I've done the oven thing before.
My Fray Bentos steak and kidney pies were never the same again!!

I've had steak and ale pies, steak and beer pies, steak and onion pies, steak and guiness pies. Loved them all.

But steak and EP90 pies are horrible.

Thanks Chaps. Drilling, as there are only the threads remaining from the plug there's not a lot to drill at. As it is extremely stuck I think it's going to be a bugger. I'll be trying heat and an easy out to begin with, I think.

All ideas and suggestions are great lads, so thanks and keep them coming.

If you only have the metal sleeve with the threads :-

I'd get a hacksaw blade and cut into the sleeve towards the thread.

Again once the pressure is off the thread it will turn.

If need be cut two slots 180 degrees apart.

Hi bollypne, may I suggest you show us a photo of the spark plug
for a closer look?

jimmock wrote:If you only have the metal sleeve with the threads :-

I'd get a hacksaw blade and cut into the sleeve towards the thread.

Again once the pressure is off the thread it will turn.

If need be cut two slots 180 degrees apart.

Now that's an idea.

Jay1969 wrote:Hi bollypne, may I suggest you show us a photo of the spark plug
for a closer look?

If I remember i'll get a pic put up, however it just looks like a small spark plug hole, no ceramics at all and it sheared clean with the hole.

Yeah I'd just get the darn thing clean outta there

I don't know if this tool will help here http://www.ebay.co.uk/itm/1-No-M10-X-1- ... 1051760696