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Old 07-27-2009, 12:21 PM   #1
BigMike0147
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Unhappy Coil Keeps Popping Off

OK. This might be a little premature, but I wanted to see what you guys thought.....

I've had my bike for over two years now with no problems. Yesterday I was riding to Pearland on the highway. I rolled into the throttle in 6th gear and my bike lost power and started sounding HORRIBLE! So, I pulled over to inspect and it died. It restarted and still sounded like trash. I saw that the coil was bouncing around in it's place. I stopped the bike and clicked it back on thinking that all was fixed, but when I started the bike it popped right back off and I could hear combustion leaking out (sounds like an exhaust leak). So I trailer'd the bike back to a buddy's and am going to tear it down today to inspect the spark plug.

What do yall think?? I'm thinking that the spark plug could have f'ed up and cracked or broke allowing compression to escape. The plugs have been in for about 2-3K miles at least. When I changed them, I tightened them to 1/2 turn past hand tight. This is supposed to be a good rule of thumb, right??

Thanks for any help or thoughts. I can let you know what I find out after this evening.
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Old 07-27-2009, 12:25 PM   #2
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loose spark plug
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Old 07-27-2009, 12:27 PM   #3
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Sounds like the plug backed out of it's threads, or pulled them out entirely.
I've seen it on 929 and other Hondas.

Try pulling the plug out and see if the threads look good.
If so, carefully reinstall it and see if it tightens down fully.
If not, your head will need to have the threads repaired.
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Old 07-27-2009, 02:27 PM   #4
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Well, I really hope that it's just a plug issue. I hope that the head isn't jacked up. Thanks for the information though! I'm ready to get it checked out today.
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Old 07-27-2009, 05:17 PM   #5
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Iv seen the pulled threads on alot of Hondas also, I spoke with Bob Wolstead from Honda about it once and he gave the custimary "Huh, thats wierd, were not aware of that" answer. He was not beeing truthful.
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Old 07-27-2009, 10:33 PM   #6
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Well, I pulled the plug (which wasn't easy), and it was what I feared. The new plug won't thread back into it now. :( It makes me sick since this is the only trouble the bike has given me yet. I'm going to look around and see what my options are. I think the threads might only be gawled right at the end.
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Old 07-27-2009, 11:20 PM   #7
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well to cut new threads you will need to remove the cyl head. ask patrick. i dunno if they will need to helicoil or some type of insert. i've never dealt with pulled threads on a spark plug hole. i guess depends on the damage done. sounds like they were overtightened
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Old 07-27-2009, 11:32 PM   #8
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I may be able to repair it without pulling the head, but stop now, don't make it any worse.
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Old 07-28-2009, 01:20 AM   #9
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Quote:
Originally Posted by Patrick View Post
I may be able to repair it without pulling the head, but stop now, don't make it any worse.
grease ftw
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Old 07-28-2009, 06:21 AM   #10
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Yeah, I think it was less than one full rotation of thread that came off. It wasn't over tightened. It must have been undertightened because it was very loose when I put the socket on it. Such a pain tho!
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Old 07-28-2009, 08:05 AM   #11
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http://www.fireblades.org/forums/hon...lug-issue.html

I don't know if you can see this thread, but it seems I'm not the first person that this has happened to. Same cylinder of the same bike....
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Old 07-28-2009, 09:03 PM   #12
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Well, it looks like the threads are toast!! I took another look at it again today and the plug fell straight through to the seat. THIS BLOWS!!
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Old 07-28-2009, 09:12 PM   #13
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I had a buddy with an F4 that this happened to, but fortunately it didn't wipe out all of the threads.
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Old 07-28-2009, 09:17 PM   #14
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So what size sparkplug thread was it?

If you really wanted to ghetto it, try to find one slightly larger, cut and thread it. yes, you will have some metal in the cylinder and its likely aluminium so its not magnetic. Get out everything you can.

Best way, and really not too much work once you start, is to remove the head and get it sleeved/repaired by a machine shop.

Always torque. the sparkplug has a crush washer that is made to compress when you tighten it.
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