How remove incorrect spark plug i.e. no clearance

How remove incorrect spark plug i.e. no clearance

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markw996

Original Poster:

309 posts

139 months

Friday 19th December 2014
quotequote all
Some fkwit has put the wrong sized spark plugs in my Aprilia RST1000 motorcycle engine.
I only bought it recently from a private seller (half way across the country) a little while ago and discovered this after attempting a basic service. The plugs should have a 16mm hex but the outer plugs on both cylinders (twin-spark) are approx 18mm. Anyone know any tricks to removing the plugs? I suspect that the threads are correct or I'm really bksed.

Problem is the clearance between the spark plug hex and the cylinder head, grinding away the head is an option but space is limited and it's got a lot of potential to go wrong, hammering on the thinnest wall socket I can find is another option.

I've got an 18mm box wrench on order which I could grind down a bit... am I missing an obvious solution?


markw996

Original Poster:

309 posts

139 months

Friday 19th December 2014
quotequote all
Thanks, my dad just phoned to say he's found a few old AF box spanners that look approx 18mm so I'm going round for a visit!

markw996

Original Poster:

309 posts

139 months

Friday 19th December 2014
quotequote all
One of the box spanners just about fitted over the top section of hex and luckily the plug wasn't very tight.

Quite amazed at what I found...

Both plugs are actually the same 18mm incorrect size, but someone had filed down the inner plug to the correct 16mm as there is even less clearance on the inner!
I didn't even notice that when I removed it.

Frightening really, if I'd done that it would have given me sleepless nights paperbag





The good thing is that the threads are ok biggrin