I broke a spark plug off in my 03 praire 650. Then I broke an easy out off in the spark plug. So can anyone tell me how hard it is to pull the head off? I am sort of intimidated by it.

 

I dont own a praire, but I doubt it would be that hard. (Much easier than getting that plug out). Spark plugs should never be more than snug. I've rode around with them finger tight before. I dont know why we think oil plugs and spark plugs need 5000 ft-lbs of torque.

You'll need to buy a new head gasket and get the torque specs for the head bolts from someone on the board here.

Put the head in the oven and get it as hot as you can stand it. (get all the oil off it first or you'll stink up the house). You need to heat it up evenly, so don't use a torch. It should come out easy once its hot. Aluminum expands more than steel. Try not the mess up the threads in the head or you'll need a heli-coil insert and a big tap.... That would best be done by a shop.

 

If you think it would be too much work, call up some atv dealers and ask for a quote. It happned to me on a minivan (spark plugs facing backward and really hard to reach) and a local mechanic charged less than $100. He said he didn't have to remove the head but spent about hour and half to get it out.

 

Yes, good idea, but I think the problem is now he has a EZ out broken off in there too. I really don't know what he is going to do now, but add lots of heat and figure some way of getting something to turn the broken plug. I dont think you can drill into an EZ out.

 

I didn't break the plug off by over tightening it. I broke it off trying to remove a dealer installed plug that was already cross threaded. I am a machinist by trade so if I can get the head off, I am confident that I can drill out the plug and re-tap it from the backside. But like I said, I am a machinist, not a mechanic. So does anyone know where I can find instructions on removing the head? Any help would be appreciated.

 

Try pdftown.com then search prarie 650 atv file is 1.76 mb