How Do I Remove a Broken Spark plug on a 2012 Super Tenere?

[Tenman]

If it was torqued to specs cross threaded. The head has to come off.

 

[Clawdog60]

This is a long shot, but before pulling off the head, I would try something like these pipe nipple extractors. Maybe one would be the right size to grab enough metal to spin it out. You may have to do some grinding on the extractor to make it fit. It's hard to tell in your picture how deep that threaded part of the plug is.
https://www.homedepot.com/p/Husky-6-Piece-Pipe-Nipple-Extractor-Set-80-533-111/304341668?MERCH=REC-_-pipsem-_-NA-_-304341668-_-N
Good luck.

Those might work after knocking the porcelain completely out. I just wouldn’t feel good about pieces of porcelain in the combustion chamber.

 

[magic]

Those might work after knocking the porcelain completely out. I just wouldn’t feel good about pieces of porcelain in the combustion chamber.

I agree. I was looking at that lip outside of the porcelain. There may be enough material there for the extractor to bite into. As mentioned, with the hex broken off, what's left of the plug shouldn't be very tight.

 

[Clawdog60]

Seems like a lot of stress on the threads knocking porcelain out though of course if it is cross threaded that won’t matter. Head removal does look like the probable option.

 

[jbrown]

Did I miss something? I don't see any indication of cross threading. It seems to me like the plug was defective, and likely broke while being installed.

 

[Clawdog60]

It was mentioned in a couple of previous posts seeing the spark Plugs did not have a lot of miles on them

 

[Koinz]

Since it broke in the threaded area, it might not take a large amount of twisting force to unscrew it. There is no clamping torque to overcome. Only the likely thread deformation, and carbon that may be built up on exposed threads in the head. It should be no where near what you need to unscrew a normal spark plug. I'd cram a screw driver in there and see if it will twist a little. If it moves at all like that, then you can figure out how to capture the fragments and hold on to it as you unscrew it.

You might be able to get to it with the valve cover off too.

 

[Don in Lodi]

Won't get you much closer, maybe 3/4". But it may give more room to work.

 

[Ritters Dad]

Update on my "shituation":
I was able to get the threaded portion of the plug out of the spark plug well, unfortunately, its now sitting on top of the piston. I'm taking the bike to a shop for engine removal and removal of the debris in the cylinder. This turned out to be a $3000 mistake-dont let this happen to you!
I'll post an update again when I get the bike back.
Thanks to everyone for your suggestions and support!

 

[RCinNC]

Ouch, 3 grand? Is that the estimate a shop gave you? For that kind of money, I'd take the engine out myself and take it to a shop.

 

[OldRider]

3 grand seems a little high.

 

[ballisticexchris]

Man that sucks!! Is there anyway you can vacuum out the debris? I would invest in a Harbor Freight camera and jury rig a small hose to my shop vac. Spray WD40 in hole to loosen debris and vacuum out. Repeat until it's clean. Please try this first before spending a bunch of money.

I don't care what anyone says, this is the reason I always put Never Seeze on spark plug threads (and everything that goes through heat cycles) before installing them. Been doing that since I was a teenager and have never had problems getting them out.

 

[Xclimation]

When I had to retap threads on a bike few years ago, I used this: https://www.amazon.com/ANBOO-Attachments-Universal-Attachment-Kenmore/dp/B077SDD6Z6/ref=sr_1_3?crid=3BV3D4G64Q8S6&keywords=vacuum+mini+attachments&qid=1567223659&s=gateway&sprefix=vacuum+mini+att,aps,158&sr=8-3
you can add various size tubing using some duct type tape. Worked good for what I needed.

 

[Tenman]

I'm not trying to be a pessimist. How could you be sure you got all the crud out of the cylinder? Some fine oily crud could get between the piston and cylinder.

 

[Clawdog60]

3k is absolutely ridiculous fee to do that. pull the head clean up head,piston and ring area, install head. I would be finding a different shop if I couldn't do it myself.

 

[regder]

3k is absolutely ridiculous fee to do that. pull the head clean up head,piston and ring area, install head. I would be finding a different shop if I couldn't do it myself.

I wonder if the engine needs to be pulled to get the head out.

Good luck with the repair!

 

[Clawdog60]

Doesn’t look like you would have to but I’ve never done it on s10

 

[EricV]

I wonder if the engine needs to be pulled to get the head out.

When my head came off for the CCT failure and repair the shop pulled the engine out of the bike. No idea if that was because they wanted to inspect the bottom end or if it was just easier to get the head off that way.

 

[Ritters Dad]

Hello fellow riders, I offer an update on my Super Tenere spark plug cundrundrum. It appears that I either torked the plug too much or the plug was defective-whatever-water under the bridge. I took the bike to the only shop in the Baltimore/DC area that had a mechanic on staff that owns a S10: 2 Wheeled Performance in Elkridge Maryland-I heartily recommend these guys.
2 Wheel Performance
6653 Washington Blvd
Elkridge, MD 21075
(410)579-2500 - Shop

Sam and the team recognized that there was no way to remove the remaining spark plug bits and pieces without removing the engine head. They did just that and were able to clean up the cylinder chamber and get the engine back together again. Luckly, I did not damage the head or the spark plug threads in my doomed attempts to remove the broken spark plug. All said and done, the repair set me back about $2500 including re-maping the CPU and clearing all unnecessary restrictions on the engine.

I have to tell you that the bike runs better than new! I constantly smoke my buddy riding a HD 104 Cu In bagger and boy does THAT feel good!

A couple of lessons:
1. Don't mess with stuff you don't fully understand-find a competent mechanic instead,
2 If you screw stuff up, be prepared to pay reasonable money to fix your mess ups.
3. Being able to ride your bike will get you through the pain of spending money. Riding will get you through times of no money better than money will get you through times of no riding!

Ride safe, have a great time, and thank the Lord for motorcycle mechanics!

 

[Ritters Dad]

Did I miss something? I don't see any indication of cross threading. It seems to me like the plug was defective, and likely broke while being installed.

Yup. That's the consensus.