The weirdest thing just happened - '05 sportster 215

[ple999]

When I last took it out, it started missing and surging, in spite of 10 gallons of fresh hi-test and a can of SeaFoam. I just tried to replace the plugs again, but the socket won't fit over the middle plug! It is the same socket I used to install the plugs, a 5/8" extra deep thinwall. I tried a standard 5/8" plug socket . Same with that. I used my endoscope: nothing in the plug well. Any ideas?

 

[MacSeaDoo]

Is it possible that that plug was not tight and is now out?

 

[JPass]

Is it possible it's a different sized plug? Try a few other deep sockets and see if something grabs. Just be careful.

 

[ple999]

I don't see how it could be a different size - they were a new set, installed with the very same socket.

Lordy, I hope it is not out. That would mean it had blown out. I had that happen on an old outboard, once, had to use a helicoil. I can reach it with my fingers: it doesn't wiggle

 

[JPass]

Can you not shine a light down there and see the hex portion of the plug?

 

[ple999]

Yes, and I even used my endoscope. Looks perfectly normal. I bought a deep 11/16 socket to try, but it won't fit in the plug well.

 

[ple999]

EVEN WEIRDER: I got up close and personal with a flashlight. The metal hexagon appears to be BLACK. The other two don't.

 

[MacSeaDoo]

Photos would help...

 

[ple999]

Photos of the 5/8" socket in a post above. Photos down the plug well not so good. I used a thin bamboo probe to feel around the sides of the plug and it feels like the plug might not be centered in the well.

I ordered a "14mm 12point thin wall spark plug socket". Arrives sometime today. Apparently it is more than 1mm smaller in diameter than the 5/8" socket.

 

[Flightjunkie]

Hi.

Doesn't this year / engine have the hollow stem valves?

My fear is that your valve failed and fell into the cylinder and smashed the sparkplug.

I hope not! Good luck. Keep us updated.

 

[ski-d00]

Something is in the hole. Did your rubber piece that holds the plug in the socket come out and stay on the plug?

 

[JPass]

The hole isn't that deep. You should be able to shoot a pic with your cell phone and post it.

It would super helpful if we could see what you're seeing.

 

[ple999]

Unfortunately, due to the nature of flash photography, they are completely unhelpful

 

[ski-d00]

Just pull the valve cover and pull the spark plug tube. Will take less than 5 minutes. Rubber gasket on the valve cover and spark plug tubes so just as fast to reassemble.

 

[ple999]

You can pull the valve cover without removing the tube? I had no idea.
Thanks

 

[MacSeaDoo]

From my perspective.

The rubber grommet from the socket was left on the plug. It melted or deformed on the hex part of the plug. (That is the black you see)

Again, just pics are not great but that what it looks like to me.

 

[JPass]

From my perspective.

The rubber grommet from the socket was left on the plug. It melted or deformed on the hex part of the plug. (That is the black you see)

Again, just pics are not great but that what it looks like to me.

Definitely plausible.

It'll be interesting to see what it actually was.

 

[rldavis]

You didn't leave the cap on the plug did you? It looks like it is on there from the pics. Could have been misfiring and causing the black you see from lack of a good connection. The rubber grommet melting does sound like a contributor as well just don't know how you would get the coil sleeve over it. Cant wait to see...

 

[Mister Magoo]

I wonder if that is part of the coil stick still on the plug?

 

[ple999]

WE HAVE A WINNER! With a little pressure, the new 12-point socket worked, and there it is: the black rubber grommet WAS the problem. I remember missing it 5 months ago, but thought it had rolled into that never-never land under the engine.

The new socket has steel springs, not a rubber grommet.

Thanks for all the help!

 

[rldavis]

Well I'll be..... You must have really pushed the coil stick on there last time to get it on the hex part of the plug... I hate those dang rubber grommets they limit you to what you can use the socket on. When I change the plugs I just loosen them then put the coil stick back on for the rest of the removal process. Glad to hear the plug wasn't pushed out by something inside..

 

[ple999]

I felt the grommet give when I tried the new socket. The 12 points gave me twice as many chances to get lined up with the hex. I think, when I pressed, the socket sheared off the lower half of the grommet.

 

[MacSeaDoo]

Glad you got it out and it was a simple fix.