Question about 2003 Honda XR 125 L

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Had to remove the head to put in a heli coil. Now i have no spark at the plug when i put it back together. Any suggestions? Honda xr 80

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Take off the plug cap place the end of ht lead close to engine if you get a spark, replace plug cap, and bobs ur uncle

Posted on Sep 12, 2009

Testimonial: "Good place to start but already tried that. No spark at lead either"

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1998 Honda oddysse blew a spark plug I want to use a heli coil to reseat the plug is there a thread size specific or any specifics I need to know when deciding what insert to buy


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they are not the same as any other helicoil for general use

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If you are unlucky, the threads will be stripped. In this case, you have 2 choices: thread repair or larger spark plug. Either way, you have to drill and tap the spark plug hole without getting any metal shavings in the cylinder. The main difference is that if you use a thread repair insert, the original spark plug size will fit in your engine; if you tap out the holewithout using an insert you will have to get a different spark plug for the cylinder that was repaired.

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Ouch! Repair requires you to remove the head from the engine and install a Heli Coil. A Heli Coil can also be installed by a machine shop pretty cheap if you take the head to them (off the vehicle of course), which is preferable since you'll want the head checked for straightness before reinstalling it.12_24_2012_6_24_24_pm.png

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Spark plugs are not screwing back in


Well that sucks so either you bought the wrong plugs or when you removed the old plugs the threads from the heads came with them. You'll have to put heli coils in the heads. Remember to use antiseize on the threads next time. always use the antiseize, this will be an expensive lesson if you stripped them.

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Honda 1986 xr 80 has not been started in several years. I replaced the spark plug and it has spark and is getting fuel but it won't start. What do you suggest?


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Honda XL200R was running great but leaked oil bad so I tore it apart and replaced the head gaskets and piston rings, put it back together now ive got no spark. The head lite comes on when I kick it but the...


well your magneto is fine(because your headlight works when you kick it over) I bet it is something as simple as you forgot to hook up a wire since you had it all taken apart. since your magneto is fine that just leaves #1 coil....or....#2 cdi box.....to find the coil just follow the wire from your spark plug to it....your CDI box should be mounted under the seat( make sure all the wires are hooked up ) and check again.....

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1 Answer

I need to get out a broken spark plug in a 1990 honda 1.6


Your local auto parts store should have Heli Coil kit or www.TimeSert.com something similar to fix you up. It's not for the faint of heart, though. Fortunately, the Accord's engine is situated to where you can reach most of the plugs.
If you've been living a good, clean life then just your plug will be stripped. However, I've never known anyone to be that lucky, and in just about all cases, the head is stripped.
You'll need to do some drilling. Get into the core of the plug with a proper bit; then, use an EZ-Out or whatever comes in the Heli Coil kit to back out the plug. The EZ Out or similar is sort of like a reverse drill bit. It bits into the plug or bolt or whatever you're trying to extract, and lets you remove it by going counter-clockwise.
While this sounds like a straightforward process, you've got to be real sure not to get any metal shavings in the cylinder head. Pistons and valves just hate that stuff.
The Heli Coil itself is a little spiral metal thing that screws and self-taps into the cylinder head. Two problems here: first, you have to make damn sure that you are putting this thing in straight. Don't want a crooked plug. Second, you're tapping into the cylinder head and there's still the danger of dropping metal filings in there. Oh yeah, a third problem: there's a little tab you must break off after the heli coil is inserted. Most of the time that drops into the cylinder head.
The Time-Sert is a solid insert and uses a different process it can be viewed here. http://www.timesert.com/html/sparkplug.html
I'd recommend drying out the inside of the cylinder and top of the piston with a good blast or two of compressed air. That way, if something falls in there it won't be stuck to the gunk inside. Might want to make sure this piston is on the downstroke so that the valves are closed. Don't want that compressed air sending junk their way.

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2 Answers

Spark plug thread broke off while trying to get it out!


Their are three options;  A tap of the proper size may clean up the existing threads. The second , is a kit called a Heli-Coil where you remove all the threads , tap it out bigger and instal a Heli-coil to bring the threads back to the original size.  The third is to tap it to the biggers size and then look for an oversized plug. I was able to do this for a lawnmower many years ago and do not know if oversized plugs are still available. 

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