• Welcome to the Two Wheeled Texans community! Feel free to hang out and lurk as long as you like. However, we would like to encourage you to register so that you can join the community and use the numerous features on the site. After registering, don't forget to post up an introduction!

Well crap. Spark plug blew out

Joined
Oct 25, 2010
Messages
3,587
Location
HUNT COUNTY
First Name
Joshua
Was pulling away from a stop sign on the old GS1000 and heard a loud POP followed by the sound of compressed air. Crap. Looked down and saw the #3 spark plug hanging down by the side of the engine.

Tried to thread back in but won't tighten down.

So I'm guessing my options are basically replace the head or helicoil/thread repair kit.

a39b251de41df8321ce7c2d9a7aaf8f8.jpg
74b6fea928ce781fb37d894d9bec2ab6.jpg
7495462c447ab0e6e7740dbf30cbb37e.jpg


Sent from my SM-G892A using Tapatalk
 
Joined
Oct 16, 2013
Messages
431
Location
San Antonio
Extreme powersports here in San Antonio installed a timesert in my klx110 head for something like $25. Heck of a lot cheaper than a new head! I like the timesert fix over helicoil because they are staked into place.
 
Joined
Oct 25, 2010
Messages
3,587
Location
HUNT COUNTY
First Name
Joshua
Extreme powersports here in San Antonio installed a timesert in my klx110 head for something like $25. Heck of a lot cheaper than a new head! I like the timesert fix over helicoil because they are staked into place.
AutoZone carries the "oem" brand thay is also staked in place. Has good reviews and is avaliable locally. I'm mainly worried about clearance between the hole and the valve seats. Not sure how much material is avaliable to do the insert repair.

Sent from my SM-G892A using Tapatalk
 
Joined
Oct 16, 2013
Messages
431
Location
San Antonio
On my KLX head the timesert is shorter than the plug hole, and just slightly longer than the plug. Obviously these two bikes are worlds apart, but maybe you'll have the same luck!
 
Joined
Oct 25, 2010
Messages
3,587
Location
HUNT COUNTY
First Name
Joshua
Just got off the phone with a forum member from www.thegsresources.com and he said he had the same cylinder blow a spark plug on a couple of years ago. Did a helicoil repair and it's been running great for the last 10 or 15 thousand miles. So looks like I'll be going the thread insert route
 

E.Marquez

Forum Supporter
Joined
Jan 2, 2006
Messages
3,746
Location
Kempner, TX
First Name
Erik
Yup
Those are your options

If you repair the head, it really should come off for the repair.

You will find or be told “ya pohieeee it can be done without removal”
Yes it can, and sure
Folks fall out of aircraft without chutes and live as well but it’s not a great plan
 
Joined
Apr 4, 2006
Messages
13,848
Location
Arlington, TX
First Name
Bill
Yup
Those are your options

If you repair the head, it really should come off for the repair.

You will find or be told “ya pohieeee it can be done without removal”
Yes it can, and sure
Folks fall out of aircraft without chutes and live as well but it’s not a great plan
What a load of.... I've done 23 of theses without removing....

Yeah, just kidding. I completely agree that he head should 100% come off for a repair like this. Or if you really want to leave the head on, a suitable plan B repair would be to just JB weld a new spark plug in place and call it good for another 50-100k miles. ;-)

Just kidding about the JB weld part of course. Besides, I don't know if JB weld is a suitable enough conductor to be used in this application.
 

SL350

Forum Supporter
Joined
Oct 12, 2005
Messages
13,140
Location
Mesquite
If this was a beater bike, you would have options. It's not. Take the head off. You can heli-coil and it will work. It's really easy once the head is off. They say timeserts are better but I have never used them.
 
Joined
Aug 5, 2006
Messages
1,041
Location
between richards and montgomery
First Name
rick
Last Name
hirsch
I only thought that happened to air cooled VW"s. On my move back home (Texas) from Hawaii, I shipped my 1966 VW to Oakland, Ca. I flew over with a 1973 Penton 175 Jackpiner in boxes as excess baggage. With a friend along, we had a huge stack of boxes and luggage. We told a porter at the SF airport that we needed to take a bus to Oakland, retrieve the VW and drive back. He assured us the massive pile was safe and to go ahead.
Ads we pulled back into the SF airport, there were tons of folks standing around. I had conducted a pre-load at home...It took us about 3 minutes to put the Penton, a tool box and 4 suitcases into the Bug, tip the porter, and burn rubber out of the loading area with most spectators amazed.
Anyway, I digress. We hauled across Ca., Nv., Az., NM... all the way to Junction, Tx and the # 3 plug blew out of the head. I screwed it back in and drove another 100 ft. We spent the night in a roadside park and waited for my Grandpa to come and rescue us.
You do have to remove the head unless you want metal fillings modifying your cylinder walls. That was in 1976!
 
Joined
Jan 25, 2005
Messages
2,822
Location
Cypress Tx
First Name
David
Last Name
Hutchinson
That's almost a project that should be done on a drill press , if the new insert is not perfectly straight with the old threads the plug gasket will not seal . The insert kit with the seat cutter will eleminate that problum . Pulling the head is the safest option because any metal chips left in the motor could cause major issues . Or they may blow out the exhaust in the first few revolutions , how lucky do you feel .
 

E.Marquez

Forum Supporter
Joined
Jan 2, 2006
Messages
3,746
Location
Kempner, TX
First Name
Erik
I'd never heard of these kits.

http://www.timesert.com/html/sparkplug.html

Thank you.

image003.jpg
Thread repair coils have been a main stay in thread repair for so long and to this day, because they work, and work very well when installed correctly.
There are also a better choice over a thread repair insert for some applications.

But thread repair inserts are better in some applications as well..
A spark plug hole repair,..,,Id use a thread insert like the Timersert. You get a spark plug seating surface that is perfectly concentric to the new threads, is at the correct angle, and in effect you get a new and refreshed sealing surface as well as new threads.

A down side is the cost of course,
$50 for a 12mm spark plug thread repair coil kit from HeliCoil
$140 plus more $$ for the inserts for the same size TimeSert kit

If the user is only going to need this one spark plug hole repaired... pull the head take it to a automotive machine shop.. Have it fixed right the first time, at a cost = or less then buying a TimerSert kit that your only going to use once.

These kits add up quickly in terms of $ invested.... quick count I have about 9 Time Sert kits and packs of inserts, and 16 Thread coil repair sets....
Let the shop absorb that investment and pay them a slight increase over what you might spend on just one kit.
 

Tourmeister

Keeper of the Asylum
Admin
Joined
Feb 28, 2003
Messages
45,979
Location
Huntsville
First Name
Scott
Last Name
Friday
Let the shop absorb that investment and pay them a slight increase over what you might spend on just one kit.
The older I get, the more I firmly believe this...

Between their vastly greater experience, the cost of me doing it, screwing it up, trying to fix it, and then eventually paying the shop to do it anyway, it is just a LOT less money and hassle to start with the shop :-P

The real trick is finding a shop that does good work. Dealerships are rarely at the top of that list... :huh2:
 

E.Marquez

Forum Supporter
Joined
Jan 2, 2006
Messages
3,746
Location
Kempner, TX
First Name
Erik
The older I get, the more I firmly believe this...

Between their vastly greater experience, the cost of me doing it, screwing it up, trying to fix it, and then eventually paying the shop to do it anyway, it is just a LOT less money and hassle to start with the shop :-P

The real trick is finding a shop that does good work. Dealerships are rarely at the top of that list... :huh2:
Dealership., or even an independent shop for this repair is an iffy thing.
Tis why I suggested an Automotive machine shop. A place that machines and rebuilds heads, blocks, flywheels, rods, cranks and the like.
They are the experts at removing broken fasteners, repairing threads.

And on may applications or projects, installing steel threads is done preventively in aluminum parts, or known problem areas in steel parts.
I do a lot of that in my builds,, steel threads for head studs, oil pan or cover studs or screw holes get steel threads. Oil drain drain threads as well if the case is already apart ..(this is one thread coils work better most times than thread inserts)

But if I did not have the stuff on hand or the thread size was not a common one, Id likely take it to a shop as well,,,,,,well ok no, thats why I have 3& 4mm repair kits with only a single coil used in the last 10 years...lol
 

Tourmeister

Keeper of the Asylum
Admin
Joined
Feb 28, 2003
Messages
45,979
Location
Huntsville
First Name
Scott
Last Name
Friday
But if I did not have the stuff on hand or the thread size was not a common one, Id likely take it to a shop as well,,,,,,well ok no, thats why I have 3& 4mm repair kits with only a single coil used in the last 10 years...lol
How much of the space in your shop is taken up with stuff that you won't get rid of because you might need it some day...? :lol2:

My superpower is getting rid of stuff like that one week before I finally actually DO need it after holding on to it for YEARS!! :doh:
 

E.Marquez

Forum Supporter
Joined
Jan 2, 2006
Messages
3,746
Location
Kempner, TX
First Name
Erik
How much of the space in your shop is taken up with stuff that you won't get rid of because you might need it some day...? :lol2::
Too much..
Spares left over from every bike my son or I raced and ride, spares from my wifes bikes..Tools made for a bearing, part to be pressed, indexed, ect on a bike model that has only been on my lift once and likely never again...

I've had two remote control Halogen work lights on the shelf for 10 years now.. Just found a use for one of them on my new trailer...Might just mount both as I'll never find another use for them....lol so might as well....
 
Joined
Jan 25, 2005
Messages
2,822
Location
Cypress Tx
First Name
David
Last Name
Hutchinson
Way back when my 950 KTM was a youngster and after I discovered what parts had to be pulled of and replaced for normal maintenance pretty much all of them got helicoil inserts in any aluminum pieces that had to have bolts unscrewed and screwed back in on a regular basis . 14 years later I have had no issues with stripped threads and I can tighten things so they don't fall off between check ups . Any thing I plan on keeping around gets whatever it needs to make sure it will stay around and stay together . I had a Penton some years ago ,it came from the factory with helicoil inserts in all aluminum parts , too bad Sachs motors were such a *** , the bike was awsome .
 

focus frenzy

Moderator
Joined
Mar 21, 2004
Messages
10,696
Location
Cleburne
First Name
Leon
Last Name
Hogan
Been there done that on my 80 GS1000g 40 miles from home at 70mph.
Had a hard time getting stain out of the seat.
Used a time sert and did it on the bike and put another 30k miles on the bike.
 

Windmill

Forum Supporter
Joined
Mar 5, 2015
Messages
2,335
Location
Thorndale
I think it is a good thing to check tightness ever so often. I just changed the Wee Stroms plugs . Rear top plug was not tight and not real smooth coming out. The new one went in fine and tightened fine. It had 20K on old one. I always use just a touch of anti-seize on all plugs. Some say don't, but I have never had a problem. Oh the loose plug was installed a factory, but probably just loosened up.. Glad I caught it. Took me six hours to change plugs and air cleaner. Speeded up when I quit following the service manual.
At least you didn't get metal in bore
 
Joined
Mar 1, 2012
Messages
43
Location
katy,tx.
Just curious, does anyone have a suggestion as to a quick fix should this happen a long way from home. I will file away the two permanent solutions should this ever happen to me. Thanks Ken In Katy.
 

focus frenzy

Moderator
Joined
Mar 21, 2004
Messages
10,696
Location
Cleburne
First Name
Leon
Last Name
Hogan
Just curious, does anyone have a suggestion as to a quick fix should this happen a long way from home. I will file away the two permanent solutions should this ever happen to me. Thanks Ken In Katy.


Well the simple fix is a U-Haul truck.
Any decent independent or most NAPA parts place will generally have the helicoil or time sert kit in stock and any additional tools needed to fix it in a motel parking lot.
Mine blew out #4 plug making it much easier, you can use a ratchet with extension to drive the tap and you coat the tap with grease to catch the chips.
Screw in a bit, pull wipe and re grease and repeat.
Use brake clean to clean the hole before installing insert.
With time sert you apply lock tight to permanently secure it.
I did mine using basic tools I already had and picked up the time sert at Napa.
 
Joined
Oct 25, 2010
Messages
3,587
Location
HUNT COUNTY
First Name
Joshua
Well that was pretty easy. Sorry didn't remove the head. Used a modded shop vac hose, grease and brake cleaner and about an hour of time taking my time and habe it back together. My kit recommend using hi temp RTV so im waiting on that cure time and I'll take it back out on the road.

Sent from my SM-G892A using Tapatalk
 

focus frenzy

Moderator
Joined
Mar 21, 2004
Messages
10,696
Location
Cleburne
First Name
Leon
Last Name
Hogan
Well that was pretty easy. Sorry didn't remove the head. Used a modded shop vac hose, grease and brake cleaner and about an hour of time taking my time and habe it back together. My kit recommend using hi temp RTV so im waiting on that cure time and I'll take it back out on the road.

Sent from my SM-G892A using Tapatalk
you siliconed the insert??:eek2: mine used the super strength locktite to permanently glue it in.

all else fails I know where a 83 1100 engine is to perk the old girl up.
 
Joined
Oct 25, 2010
Messages
3,587
Location
HUNT COUNTY
First Name
Joshua
That's what the kit directions specified. This kit also staked the insert into place instead of relying on loctite. So I assume it's for sealing purposes not lock purposes they specify RTV.

Sent from my SM-G892A using Tapatalk
 
Joined
Mar 27, 2017
Messages
127
Location
SW Austin
My ford triton 5.4 had three time-serts, as at about 100k miles it developed a habit of spitting spark plugs out. 3 in 10k miles.

The head never came off, obviously a lot less practical in that case than on an air cooled bike. Time-sert even makes a special kit for ford triton motors it's so common. Local shop had done loads of them. Drill slow with grease to catch filings, then they'd spray a bunch of carb clean in there (to rise off any grease/filings), then used a shop vac with a thin hose to suck it out, repeated a couple times. None of them ever failed in the brief remaining time I owned the truck.
 
Joined
Nov 20, 2012
Messages
1,241
Location
Waco
First Name
Rob
Just curious, does anyone have a suggestion as to a quick fix should this happen a long way from home. I will file away the two permanent solutions should this ever happen to me. Thanks Ken In Katy.
Aluminum foil could perhaps thread the gap, and if you don't have that then use some wood, like maybe pieces of a couple of tooth picks or really small sticks if you are in a pinch, but just make sure the wood or the aluminum foil don't go beyond the hole or too close to the spark plug boot.
 
Joined
Oct 25, 2010
Messages
3,587
Location
HUNT COUNTY
First Name
Joshua
Just curious, does anyone have a suggestion as to a quick fix should this happen a long way from home. I will file away the two permanent solutions should this ever happen to me. Thanks Ken In Katy.
The kit I used is available at all the big box parts stores you pass on the road and can be done in a parking lot with a few extra tools you buy or borrow from the store if need be.

I limped home on 3 cylinders 20 miles this go round but could have rode to the store it was closer haha.
 
Joined
Apr 26, 2006
Messages
4,044
Location
Seabrook, TX
My kit recommend using hi temp RTV so im waiting on that cure time and I'll take it back out on the road.
That's interesting. Was the kit generic 14mm or specific for spark plugs?
I recall RTV isn't reliable around gasoline. But maybe there's some newer stuff that is fuel resistant. :shrug:
 
Joined
Oct 9, 2007
Messages
11,261
Location
Far East DFW
My ford triton 5.4 had three time-serts, as at about 100k miles it developed a habit of spitting spark plugs out. 3 in 10k miles.
I guess that's lucky. Seems like an easier fix than the triton 5.4's that decided to seize the spark plugs in place allowing them to be broken off. :eek2:
 
Joined
Oct 25, 2010
Messages
3,587
Location
HUNT COUNTY
First Name
Joshua
I guess that's lucky. Seems like an easier fix than the triton 5.4's that decided to seize the spark plugs in place allowing them to be broken off. :eek2:
I had a 08 Mustang with the modular V8 and when I did the plugs on that car I soaked the plug wells with penetrating fluid for a solid 24 hours before i even attempted to take them out.

Sent from my SM-G892A using Tapatalk
 

E.Marquez

Forum Supporter
Joined
Jan 2, 2006
Messages
3,746
Location
Kempner, TX
First Name
Erik
I had a 08 Mustang with the modular V8 and when I did the plugs on that car I soaked the plug wells with penetrating fluid for a solid 24 hours before i even attempted to take them out.

Sent from my SM-G892A using Tapatalk
There are a few learned tricks to get these out every time no risk or damage
and not overnight soaking and it is the most counter intuitive way possible but works....impact gun......I cringed the first time heard from a tech about this way and worse the first time I did it..but have since done a dozen or more motors now and it just plain works....
 

JMZ

Joined
Nov 15, 2005
Messages
6,097
Location
Gonzales , TX
First Name
John M.
Last Name
Zavadil
My daughter asked my wife a while back if I would change the plugs on my son and laws 05 F150 . I said NO :eek2:
 

JMZ

Joined
Nov 15, 2005
Messages
6,097
Location
Gonzales , TX
First Name
John M.
Last Name
Zavadil
Lol. Idk. My buddy that was a Ford mechanic forever said he uses a wore out impact on them. They took it to Ford to get it done .
 
Top