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Greetings---I just bought a non op 1981 GL1100 and found that they had stripped and re-drilled one spark plug hole. They drilled the hole so large that I cannot use a heli-coil. (It has an old monster spark plug in it.) How have you guys solved this problem? Is there any way to salvage this head? Thanks, Lew
 

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Monkey with a Football
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I'd just get another head off of eBay if it were me.
 

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If the hole is too big for a Helicoil, I would say it is not worth spending time or money on.

Get a replacement head on Ebay. They are not expensive.
 

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Token Canuk
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The Ferret always comes out on top :cheeky1::cheeky1:
 

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Monkey with a Football
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We are warmer down here so our reaction times are faster.
 

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Token Canuk
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:p:p:p:p:p:p:p:p it's still -25 with the sun on the thermometer.
 

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96aspencade wrote:
:p:p:p:p:p:p:p:p it's still -25 with the sun on the thermometer.
Then get you old bones in that hot tub!:cheeky1:
 

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I used to work on air cooled VWs that was a common problem.KD tools uset to have insert that were made like a bushing instead of like a coil they worked fine on a lot of oversized plug holes.
 

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Token Canuk
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SB in SC wrote:
96aspencade wrote:
:p:p:p:p:p:p:p:p it's still -25 with the sun on the thermometer.
Then get you old bones in that hot tub!:cheeky1:
Ya, Santa had to take it back :gunhead::gunhead:
 

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Monkey with a Football
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96aspencade wrote:
SB in SC wrote:
96aspencade wrote:
:p:p:p:p:p:p:p:p it's still -25 with the sun on the thermometer.
Then get you old bones in that hot tub!:cheeky1:
Ya, Santa had to take it back :gunhead::gunhead:
No I didn't. It's just covered with snow. And deer piss.
 

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oldmisterbill wrote:
I used to work on air cooled VWs that was a common problem.KD tools uset to have insert that were made like a bushing instead of like a coil they worked fine on a lot of oversized plug holes.
I've used those before also in my old sand rail. They work better than helicoil, but I still think you're better off with used head.

You might post a wanted thread in the "For Sale" forum. You might find a member with an extra lying around.;)
 

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Gotta gl1100 head for sale, setup for left side , 25.00 plus shipping , about another 20.00 in great shape. picasso.
 

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Discussion Starter #14
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Thanks for the help. How do I measure the size and thread count of the much larger spark plug? Thanks, Lew
 

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I have a set of metric & NF & NC thread gauges plus a plastic board with labelled metric holes in it. Very useful.
You could see if a 14mm sparkplug will screw into the hole & that would tell you the size. The thread pitch is probably 1.25mm
 

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I would go for the used head for $25 instead of messing with oversized plug which can't be the same as oem plugs. May end up with other problems due to differant plug heat range ect.
 

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The larger insert that I have used that looks like a bushing is called a Keensert.

Do a search and you will find pictures and instructions.

The Keensert is much larger than a helicoil and should fix your problem.

Our local NAPA carries them in a kit with the proper sized drill and a disposable driver.

After installation there is four stakes that get driven down through the threads on the outside to lock the insert in place.

This is a quick and cheap fix to see how the engine runs before you spend money on a head you may not need if the engine is trashed and only good for parts.

Your choice.
 

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I would only use those helicoil in non structural/ non stressed application as last resort. I had been in a boat where the sparkplug blew out like a bullet.

Used head a good idea.
 

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Disfunctional Nimatode
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I'm with OldMisterBill............ I took a head for a 6hp evinrude outboard to my machine shop. They drilled out the head and put in a bushing that scewed into the head, and the spark plug screwed into the bushing. Works perfectly.

luv U longtime.

Dancinbear
 

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The keen sert allows you to use an origional spark plug.-never had a failure with them.The good thing is you are now installing the plug into a steel threaded hole instead of aluminum or Magnesium so galling is not a problem any more.
 
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