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Removing sheared spark plug? Removing sheared spark plug?
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Old 10 Jun 2011
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Removing sheared spark plug?
One of our desert-bashing Dominos delivery bikes (a Honda Innova 125) has a bit of a problem. On attempting to remove the spark plug the plug sheared in half, right down at the start of the thread.

Does anyone have a genius idea for removing this - we have tried a stud extractor, it's just milling bits of plug out. We have also tried a load of penetrating fluid and heat to get it moving, and a copious amount of swearing which seemed to have no affect at all.....
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  #2  
Old 10 Jun 2011
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sheared plug
When verbals fail, then science has to take over.
My experience is to take the top off, make a tool to fit the electrode, maybe a bit of pipe with a slot in it, attach a long lever, and back it out. You will not get many chances, so go slow and powerfull.
If this fails you will have to mill it out using specialist equipment, any machinest workshop will bill you for an hour, and they pay us well.
Good luck.
Peter, in Oslo
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Old 10 Jun 2011
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I had the same and ended up taking the head off and drilling the remains out to a diameter marginally less than the plug diameter. I then managed to pick out the thread remains and clean up the head threads with a tap. This was a pain to do and now I think I would just drill it out and fit a helicoil or similar thread insert. Depending on the bike you might be able to do this in place - if you try this heavily grease the drill and taps to try and collect as much swarf as possible. Good luck
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  #4  
Old 13 Jun 2011
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Is there enough of the plug left to use some chemical metal to bond a screwdriver to it?

Let the metal set then unscrew.

Use the biggest driver you can and de-grease the area well before you use the chemical metal...
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Old 14 Jun 2011
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can you post a photo so we can see how much metal is left ?

if you cant start it turning with a small punch and hammer, try milling a slot in whats left with a dremel for the screwdriver and liquid metal trick....anything to give it more purchase.
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Old 14 Jun 2011
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I've only done this once so cant be sure that it will work every time.

Tools; drill and bits, diameter to suit a junior hacksaw blade, junior hacksaw or a bowed piece of steel to use as the hacksaw frame, bent to suit the shape of the head.

Make sure the head is off. Drill a hole out in small steps until you can easily put the junior hacksaw blade through the hole. Hook up the hacksaw to the hacksaw frame or bowed steel. If you cant do that then try some wire around the blades end hooks to give you a bit more leverage.

Slowly cut through the side of the sparkplug, do another cut opposite. Make sure you only cut the plug and not the head.

If the old plug does not drop out, use a screwdriver to turn the plug out.

Going slowly is paramount so that the thread is not damaged.
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Old 16 Jun 2011
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Caveman approach.Bash a big torx bit into it and try and wind it out.Don't blame me if the engine gets smashed to pieces though.
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