Left one of them in the head. The plug threads stayed but the part the wrench should remove came out with the whole insulator.Weird. Guess it's time to pull the head unless some has a better idea??? These are so rusty I wonder if theyve ever been changed.

 

Any tips on pulling the head onthe right side?

 

I would try to get an ez-out or something in there first before I pulled the head. This is not an uncommon experience, and they make tools to remove the plug piece without pulling the head off. Check at your local parts store. Put lots of penetrating oil on it, let it soak for a day or so, and try the extractor tool. Put a reducer and a piece of rubber or plastic hose on a vacuum and suck out any shavings from the cylinder after you get it out.

 

When you install new plugs, I recommend using Anti-Sieze on the plug threads.

 

I agree. I'd try an ez-out. I had a plug breakoff in a dirtbike like you are describing and it came right out with an ez-out.

 

Before using an EZ out spray the broken plug or thread that stay in with wd40 and let it soak for maybe an hour and try to remove it. Good luck

 

they have this penetrating fluid called pb blaster. get that it will be better then wd-40.

 

AAARRRGH...I have now lost the tip (about 1/8") of my locking needle nose pliers down the hole while trying to turn the portion that I can grab. One side/tip just popped off and fell in the hole! Assuming I get the stupid thing out, how to I retrieve that part?

 

Wow. Go to a local tool store and see if they sell one of those little grabbers. It has three claws on the end and should be small enough to fit into the bore. Looks like you're going fishing. Good luck getting all of that out and not having to pull the head.

 

Try a small magnet taped (taped really, really,really..... good) to a small but siff piece of wire that you can direct around to different parts of the cylinder. Maybe to help out, you can turn the motor by hand until that piston is at the bottom of the cylinder. That way you might be able to get the angle to see the piece down there.

I also removed a broken plug w/ an ez out.

Good Luck.