Kawasaki Vulcan 900 - Fouls Plugs

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Sep 10, 2005
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Location
Erie, PA
2007 Vulcan 900 Classic LT: In the year 2016 at 1,400 miles. Father started it, drove it around the owners block, shut it off, loaded onto trailer. On the trailer ride home the dew set in, and upon starting it late at night, it fouled a plug and I could not recover it at all. No amount of cooking it on a stove or using a torch would clean it. I replaced them both the next morning. Bike has 10k on it now and all is well on that set of plugs. I am now wondering what real interval to change them.

2006 Vulcan 900 Bobber Conversion: This is a bike I converted into a bobber using the blue collar bobber kit, and I bought with 11k. Original plugs were fouled because prior owner did not fish the new stator wires thru any grommet, rather cut the engine gasket and pinched them on purpose when mating the engine case, then he applied elmers wood glue thinking that would seal it up. It actually was pushing 35v into the ground of the bike messing up the fuel and spark. I fixed all of that in 2016, and have put about 6k on it without any issues. I bought that set of genuine NGK plugs at a local dealer and both fouled out. (one on each ride). Both times I beat on the bike super heavy, and "rung its neck". It backfired out one pipe and I lost that cylinder. Something about the high revs caused one to fail.

I am very concerned about this, these plugs are not easy to change on the side of a road and the bike can hardly move on one cylinder. How do I prevent fouling, and how often should these small NGK;s be changed? The engine does not use a drop of oil, and the plugs always look nice and clean like they are properly burning. I installed all my old plugs I saved and not a single one will work, even when sitting in a junk drawer for all those years.
 
I should clarify. If I hook the plug to the wire it sparks fine. Install in cylinder, and its dead.

No visable fouling
 
Perhaps slightly off topic - but I have never heard of restoring plugs though “cooking them” on a stove.

And you don’t “burn” them with a regular torch - it’s an oxy-acetylene to heat them up and then go rich on the oxygen, to burn up the carbon.

All that to say, that I don’t reinstall plugs with a problem.

Ever.

I may pull them to examine, but if they’re dodgy, they get replaced.

So, why would you put these back in when you had a misfire and they looked bad enough to try “cleaning” them on a stove?
 
I had that problem on an old Suzuki Katana. Bike sat over winter. Spark plugs looked only slightly dirty (carbon), bike would not start no matter what I did. Pull plugs...they would spark when laid on the head. Clearly it was getting air and gas...went to the local shop, and he told me to put new plugs in. Followed advice, and she started right up...couldn't believe it.
Never figured out what caused it, all I know is it has never happened again since on that bike or any I have ever owned. This was all 4 plugs, and just looking at them, you would not have known.
 
Perhaps slightly off topic - but I have never heard of restoring plugs though “cooking them” on a stove.

And you don’t “burn” them with a regular torch - it’s an oxy-acetylene to heat them up and then go rich on the oxygen, to burn up the carbon.

All that to say, that I don’t reinstall plugs with a problem.

Ever.

I may pull them to examine, but if they’re dodgy, they get replaced.

So, why would you put these back in when you had a misfire and they looked bad enough to try “cleaning” them on a stove?

agreed, if I go through the effort to pull plugs, I already have a backup, and will most likely use it unless the ones I took out look pristine.
 
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I attached photos of all the old plugs. They are rich if anything. Anyways when a plug fouls, from my younger years, sitting in a can or drawer for many year fixes them in most cases. In the case I did buy new. Motorcycle is critical not to break down
 
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