Spark plug extraction advice!

Alright, bear with me on this one. Last weekend I started to change the spark plugs on my 2003 KV6. Started with #5, no worries. Wrestled with #3 for a while before moving on to #1. Did 2, 4 and 6 fine.

Went back to #3 and I can't for the life of me get the little sod out. Have tried different spark plug bits.

It's not that it's stuck .... It's that I can't even seem to get a tool on it. As I said, all other 5 tool went in, bit of resistance but carefully they all came out. This one though there's nothing. No resistance at all.... As if the tool part of the spark plug tool doesn't engage.

I'm at a bit of a loss. Have tried rigging up a video camera and light to figure out what's going on. I'm at least fairly sure there is a spark plug in there but none the wiser as to what's going on.

Any thoughts or input gratefully received!

when you say wrestled with do you mean applied a lot of force to undo? are you able to get a clear view into spark plug hole even a glimpse so you can see top of plug thread? has your plug socket got a rubber insert to "pick up plugs"? as it may already be loose or broken? failing that try a multi spline socket insted of a normal plug socket, has worked for me in the past.

If it's a roght pig to see use a iPhone or other and photo it so u have a better view of the problem I have done this many times and can make the world of good in hard to see places

adrianscarff said:

when you say wrestled with do you mean applied a lot of force to undo?

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No... I mean I didn't even get to that point. Put the tool down there and nothing... It's not like it's stuck... The tool just spins and spins (both directions) like the plug is just free balling it down there. it's like the thread has gone... But I don't want to think about that.

are you able to get a clear view into spark plug hole even a glimpse so you can see top of plug thread?

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Yeah, just about, will post it up in a bit.

has your plug socket got a rubber insert to "pick up plugs"? as it may already be loose or broken? failing that try a multi spline socket insted of a normal plug socket, has worked for me in the past.

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Yeah have tried two different 10mm plugs both with the rubber inserts. Like is said, the other 5 plugs were fine. Have a 12 and 14 but they don't fit in the hole!

I'll have a look what other sockets I have!

matt1295 said:

If it's a roght pig to see use a iPhone or other and photo it so u have a better view of the problem I have done this many times and can make the world of good in hard to see places

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Yeah... Tried all sorts of things. Managed to get something with a small flashlight and a video cam.. Will post it up.

It's always the hardest plugs to reach give the most trouble. I've see them cross threaded and over tightened which strips the threads. Isn't number 3 where you had the misfire and a noise? Sounds like the plug isn't holding in the thread, just spinning and rattling around. I've seen this a few times. The only remedy that would be replacement head.
Fingers crossed it isn't.
Pictures would help

Nodge68 said:

It's always the hardest plugs to reach give the most trouble. I've see them cross threaded and over tightened which strips the threads. Isn't number 3 where you had the misfire and a noise? Sounds like the plug isn't holding in the thread, just spinning and rattling around. I've seen this a few times. The only remedy that would be replacement head.
Fingers crossed it isn't.
Pictures would help

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I thought rear bank would cause most grief. But they were all fine! The front 3 were harder, less room to work in... And this one which I reckon should be easiest of all 6!

It was cyl 2 that the diagnostic said had the misfire... Not this one...

Same damn thing happened on my old CBR600 and that was a new head. really hope it's not that here. at least when that happened i could get the plug out... this one won't come. even with a bit of hose pipe etc which would definitely grip the head of the plug if it was loose in the chamber... (i assume.. )

Here are some pics. I screengrabbed them out of a video.

What you can't see is what's going on with the top of the plug ... the bit where the tool would grab. Will try again to get a shot... if it stops ****ing down

It is unusual to have major problems removing the odd bank plugs, like I said, it's normally it's the rear even back that gives most trouble.
All I can think of is there is a slight narrowing of the plug hole, down near the plug top. This could be preventing you from getting the socket onto the hex.
Look at the outside of your socket for scuffing.
If you feel the plug is turning, try turning it a small amount then take a picture, turn it again and take another picture. Comparison of pictures should reveal if the plug is actually turning.
All looks normal with the plug though.

The plot thickens. Have a look at the attached. This looks to me to be silicone sealant or similar. Which is blocking the spark plug tool from getting down to grab the hex.

Which is interesting - when the other plugs came out they did have some black rubber / silcone sealant on them. And then you can see it spilling out of other areas on the cylinder head.

Is this common / normal - to replace the usual top gasket with silicone?

And any thoughts on something that might dissolve it?

Was the plug lead boot intact? I does look like sealant though. I'd use a long hooked implement to pick it out.
The cam cover uses a gasket, no sealer should be necessary.

Looks like someone replaced the cam cover gasket with silicone/mastic or somfink...

Yep as Nodge said try a pick to loosen it, you don't really want any going down the plug hole so you could give it a vacuum before removing the plug!

You could also remove the cam cover to get to the problem area.

I was thinking the end of the plug lead as well

See if a high pressure air line will blast the bits out.

ianda12 said:

See if a high pressure air line will blast the bits out.

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I just tried the vacuum cleaner on it.... No joy

I'll get the compressor out! :violent:

weirdbeardmt said:

I just tried the vacuum cleaner on it.... No joy

I'll get the compressor out! :violent:

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You need a prodding tool to help break it up.

Nodge68 said:

You need a prodding tool to help break it up.

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Get a flat blade screwdriver and spareness it with a finder and cut through it in stages

matt1295 said:

Get a flat blade screwdriver and spareness it with a finder and cut through it in stages

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Spareness it with a finder?

Sharpen & grinder bloody typing is shocking today

matt1295 said:

Sharpen & grinder bloody typing is shocking today

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Mind on other things? Old ladies perhaps