XL 600 Spark plug hole
 

Hi I just bought a XL 600 1986 model
I tried to remove the spark plug, the plug was not very tight and just kept turning but wont come out. I tightened it up as much as I dare It is not very tight but bike will run.
I will have to get the plug thread repaired.
So suggestions on
How to get the old plug out
How to repair the thread, is it possible to repair with out removing engine
The bike is in fair condition for its age but shows 85 thosand kms is this high for this type of engine I think it has had regular oil and filter changes.

Bolla,

Go to NAPA and buy a heli-coil kit for a 12mm. Heli-Coil ( HeliCoil Inserts ) Helicoils Screw Thread Inserts | Emhart.com
Kick the engine over SLOWLY until you feel the BEGINING of compression. STOP

Get the old plug out somehow, without worrying about the threads. Then put lots of grease on the drill bit (keeps most of the filings stuck to the grease) and turn it slowly until thru. Then tap (comes with the kit) and make sure you keep it straight as you tap new threads.

Then spray alot of brake cleaner in the hole, then quickly kick it over to wash out any metal. Follow directions for inserting the heli-coil. Be careful breaking off the tab (that it doesn't fall in. Put grease to catch it on the end of the plastic inserter.).

Wala! :D Good as new and you didn't have to remove the head.

Toby (charapa) Around the Block 2007 |

Xl 600 R
 

Hi just bought a xl600 r..having trouble getting the plug out....
Have tryed a 21 mm and 16mm spark plug socket,,,but nothing seems to fit.
Is a special tool needed to get it out?
Thanks Kev

Yes, it is a very tall 18mm, comes with the stock kit, or you can get one from your Honda dealer. Or, you can get an 18mm plug socket and tack-weld a 2" extension (3/8) together with it. then you can pull it out.

When you put the new one back in, put 'Never-Sieze' grey grease on the threads and you will never have trouble with that plug getting it out 5 years from now.

Toby (charapa) Around the Block 2007 |

All done by trial and error
 

The Yam TTR600 (or TT600R if you prefer) has the same issue, with a very deep spark plug. After trying every spark plug spanner I have ever owned, + a few, I solved it by buying a new, very deep spark plug socket (but not so deep that it fouls the frame above the engine) combined with a socket set universal joint and the rachet drive.
Even then, this whole arrangement fits only in one particular position under the bike frame/fuel tank and it turns the plug about 1/4 - 3/8 turn at a time: enough to tighten or slacken the thread.

spark plug
 

Thanks for the help guys...will get a 18mm tube socket.
Regards KEV

Get it in 3/8 drive and also a universal socket.

If you get a cheap-ish 18mm box socket,cut it down to the right length and weld on a 17mm nut,you'll be able to get a normal 17mm spanner on it even with a large LM tank fitted.