Tried ez-out

[SiP]

Snapped a spark pug off in the head trying to change it.
Had some great advice on things to try - one of which was to knock out interior of the plug and then use an ez out.
Anyone have any ideas now that the ez-out snapped off as well - or am I into a head strip now
I was so sur it was gonna come out to

[John]

Here's how I did it

http://www.xs11.com/forum/showthread...rk+plug+insert

[SiP]

I don't think I explained properly - sorry. The actual ez-out snapped, so now I have the remaining outside (threaded part) of the spark plug in the hole still and the ez-out inside it - snapped of nicely level with the top of the spark plug hole. I'm under the impression that they're quite a hard metal so I'm thinking I'm screwed and need to pull the head off to take it to a machinists.
If anyone can save me that drama - well it's worth a beer!!

[Ken Talbot]

How much wall thickness is left outside of the ez-out? Would you have room to go in with some fine diamond burrs in a Dremel tool and grind away the remains of the plug threads without damaging the aluminum threads in the head? The diamond burrs will also remove the broken ez-out, but it is a slow process.

Another thought - grind a screwdriver slot across the ez-out, then use a straight bit in an impact driver to break it loose.

[SiP]

good thoughts ! I have the thickness of the spark plug metal that has the threads cut in it that surrounds the ceramic insulator. At a guess probably 1/16th of an inch or less.
I don't think the diamond burr is possible (don't have one anyway), but I might be able to cut a slot and I have an impact tool so I'll look at that tomorrow.
Thanks

[SiP]

Incidentally - if I remove the head and take it to a machinists, do you think that they can repair it as per original specs or will they drill it out, re-tap it and I'll have to use a bigger size of spark plug?

[rneal55555]

It would be worth a six pack but I'm not gonna collect it. Because at this point I'd just pull the head too. There maybe a way out of it but I don't know what it is.

[mro]

Bummer

Sounds like you may have needed a little penetrating oil and heat.

Carbide drill bit will go through an easy out. Problem is having enough room to get drill motor in position. Want drill bit to turn at low speed with good pressure behind it. 1/4 inch bit can handle pressure pretty good, spend extra time to make sure you get hole started in center.

Not enough room, off with her head........



mro

[SiP]

lol

[mainlylinux]

Try getting a can of "canned air" and flip it upside down. Spray the contents on the remaining part of the plug that's sticking out - it should get very cold.

Maybe if you get the plug cold enough it will come out.

I'd also try some localized heat on the head and penetrating oil.

Anti-sieze is the way to go once you get that baby out.

Also go 1/16 of a turn out, then the same back in, alternating, continuing to use the oil.

Snapping bolts and stuff off is a drag.

Good luck.

Dan

[Lloydo]

I'd pull the head, same exact thing happened to me. I bought the bike with the plug that way, & snapped an ez-out in half. I took the head to a local shop here, they put a helicoil in, re-ground the valves, & " boiled" the head. The whole thing only cost about $140. That's just for the shop, gaskets & stuff were of course extra, but the piece of mind was priceless. You'll have to re-do the valve shims if you have the valves ground, but with a clymers manual, & this site, it's a lot easier than you might think.

[GNEPIG]

.. bummer, sounds like it's over.
we have a place here that laser cuts out our botched attempts at removing broken off exhaust studs, of course we have to remove the head and bring it to them. you should have a place like that too, start calling the machine shops and ask around.
..a broken off exhaust stud with a broken off ez-out inside cost about 70 bucks to remove, a broken off spark plug with ez-out should be a breeze.
and they dont mess up the threads in the hole at all.

..if you would like to call and ask about how they remove the broken off parts, for reference of course, the place is called
Aaron Tool inc in bradenton fl 941 727 8319. they should give you an idea of what kind of service to look for in your area.
hope this helps

[Geezer]

You can drive the so-called EZ-out out from the inside with a punch. A couple of light taps should do it.

The couple times I had to remove a broken plug, I used a Snap-On broken bolt extractor and the plug came out easy.

I'd bet that plug is really sized or it would have come out without snapping the tool. You may need to take the head to a machine shop to get the broken pluig out.

Geezer

[Ken Talbot]

If you end up taking the head to a machine shop to have the ez-out and old plug body replaced, you may not have to do anything more. If the original threads get $crewed up, they can put in a helicoil insert and you carry on with your regular plugs. If you go that way, for the minimal cost inviolved, you might consider having helicoil inserts installed in all four holes while the head is off.

[excess11]

Crazy!!

Here is a crazy idea!!! Start the bike and run it on 3 cylinders for a while. Maybe the heat,compression and vibration will loosen something up!!