Technical information

Spark Plug Analysis

Appearance of a used spark plug tells a lot about the operating conditions of the engine and the
plug. Thus the analysis of a plug plays an important role in the maintenance of a car.

1 : Carbon Fouling
Carbon fouling is the most common spark plug related failure, but is not a spark plug fault.
Carbon deposits are conductive, and as they accumulate along the insulator nose they reduce the
insulation resistance of the spark plug. As electricity always takes the path of least resistance a
misfire may occur if a significant amount of carbon deposits accumulate. A spark will not form
as electricity can track along the conductive carbon deposits to the metal shell (as shown in red
below) rather than forming a spark across the electrode gap which has a very high resistance.

As mentioned the optimal operating temperature range for a spark plug is 450 870C, 450C is
the spark plug self cleaning temperature at which point carbon deposits will burn off. However,
if too cold a spark plug is used and this temperature is not achieved carbon fouling will occur.
This is the most common reason for carbon fouling.

Other causes for carbon fouling include:

Causes
Air/fuel mixture (A/F) too rich

Corrective actions
==>

Incorrect adjustment of carburetor

It is necessary to service the carburetor, the au

choke system or the fuel injection system.
Faulty auto choke system
Faulty fuel injection system
Faulty electrical system

==>

It is necessary to service the electric system

Poor connection of high tension cables

Inadequate running conditions

==>

It is necessary to run at higher speeds (about 8

km/h) from time to time.

Prolonged idling
Continuous low speed driving
Too cold a spark plug

==>
Use a hotter spark plug
(Example: BK R6E-11 --> BK R5E-11)

Air cleaner contaminated

As carbon builds up, the insulation resistance of the spark plug drops and the voltage generated
by the ignition coil is reduced. When the generated voltage becomes lower than the required
voltage of a spark plug (the voltage needed to cause sparks at the spark gap), sparking is
suppressed and mis-firing occurs.

2 : Terminal Nut Wear

Excessive vibration of the engine may lead to abnormal wear of the terminal nut.
As a result, the cover may come off the plug. For vehicles whose engines vibrate more than
others, such as watercraft and snowmobiles, solid post terminal plugs with excellent vibration
resistance and wear resistance are recommended.

3 : Flash-Over - Spark leakage from terminal to metal shell

Flash-Over When the spark gap has widened due to wear of the electrodes, a higher voltage is
required. The flash-over occurs when the required voltage between the plug electrodes is higher
than the voltage flying between the terminal and metal shell.
The plug cable material hardens as time elapses, which in turn reduces the tightness of the cover
and insulator, lowering the preventive power for flash-over.
As a higher voltage is required for a turbo charged engine, flash-over is more likely to occur. It is
important to recognise that a plug cable is a consumable part which needs to be replaced

periodically. When there is no spark after washing the car or the engine room, check whether
water has entered the plug cover or not.

4 : Corona Stain

A removed spark plug sometimes has discolouration around the insulator surface which looks
like gases have leaked between the insulator and the shell.
It is not a stain caused by gas leakage but by corona discharge (Carona Stain).

Mechanism of corona discharge

The high voltage applied to the spark gap is also applied to the area between the centre electrode
and the metal shell, causing an insulation breakdown of the air at the gap (a) between the
insulator and the metal shell. The phenomena is called a corona discharge. The generated carona
discharge develops toward the terminal nut. This last process is the pale blue carona discharge
that is observed at night.

5 : Metal shell - Rust, breakage at caulked portion

When water has entered the plug hole due to water resistance of the plug cover or, in the case of
a motorcycle, when water has accumulated due to the inadequate draining through the plug hole,

Rust
the metal shell may rust.

The Caulked Portion

The rusting of the metal shell causes no deterioration of the function of the spark plug. Note,
however, that water inside the cover may prevent sparks from being generated.
If the plug is forced to remove when the returning torque is abnormally high due to some causes
such as plug thread seizure, the plug may break at the caulked portion of the metal shell.
When returning torque is high, the engine should be first warmed up. Then, by spraying
penetrating liquid around the plug thread and leaving it for a while, the plug can sometimes be
removed more easily.

Broken Ceramics

Melted Electrodes

Deposits

6 : Firing End - Broken ceramics, melted electrodes, deposits

When the firing end of the plug has overheated, the ceramics may break or the electrodes may
melt.
Under usual engine condition, the plug does not overheat. Note, however, that it gets extremely
hot in the case of abnormal combustion (ex. high - speed knocking, pre - ignition).
When the A - F setting is lean due to a faulty fuel system, the combustion temperature may rise,
resulting in abnormal combustion. The engines cooling system may be faulty. When the spark
timing is too early, the combustion temperature may rise, resulting in abnormal combustion.
When deposits (generating from combustion) are accumulated in the combustion chamber, the
combustion temperature may rise, resulting in abnormal combustion.

When deposits have accumulated on the firing end of the plug, deposits may overheat, causing
abnormal combustion. Especially in a two - cycle engine, oil gets burned and remains in the
combustion chamber as deposits, accumulating on the plug as well. It is necessary to remove
these deposits periodically.
In engines that consume larger amounts of oil, oil may enter the combustion chamber. It is
necessary to check the amount of deposits during inspection of the plug. Burning of oil can also
be detected by visible white exhaust gas emitted from the tail pipe.

7 : Dry and wet fouling

Wet fouling is fundamentally similar to carbon fouling. Although the root cause may vary due to
a number of reasons, in essence the insulation resistance is reduced allowing a spark to track
along the insulator nose and earth to the metal shell rather than forming a spark across the
electrode gap as desired. Please see 1. Carbon Fouling

8 : Insulator - Breakage at the corrugation and caulked portion

Caulked portion
Corrugation
When removing or installing the plug, the plug wrench may slip or be tilted and may hit the
corrugation of the plug against the inside, breaking the insulator.
Depending on the type of plug wrench, the plug may break at the caulked portion of the metal
shell. This may not be noticeable from the outside appearance.
Slipped wrench leaves a mark on the hexagonal portion of the metal shell. A plug wrench with a
definite hexagonal shape should be used. A rounded or loose wrench should be either avoided or
used with special care.

9 : Under or over tightening

Too tight
Too loose
When the plug has not been tightened enough, the combustion gas leaks out the thread portion.
This reduces the radiation of the plug, causing the metal shell to be heated, resulting in
discolouration of the metal shell plating. If the metal shell continues to overheat the plug
temperature may rise and abnormal combustion may result.
When the plug has been tightened too much the thread neck portion of the metal shell will be
lengthened. When the threaded neck portion is lengthened, the insulator and metal will not seal
tight enough, causing the combustion gas to leak. When the gas continues to leak, the plug will
be overheated and abnormal combustion may result.
The plug should be tightened to the following recommended torques and turning angles.

When the plug is tightened too much the metal shell thread neck may be broken
at around the first to second thread.
The plugs with smaller diameter portions, the D (12 mm) or C (10 mm) types thread neck portion
is not very strong. Observe the recommended torque and turning angle and tighten with special
care.

10 : Plug socket troubles

Damage to spark plugs during installation can easily occur and will oftern result in an
intermittent misfire or no spark at all. Care must be taken during installation that the spark plug
socket is not slanted and does not slip causing insulator breakage (See Figure 1). Internal damage
can still occur without the insulator actually breaking. Any horizontal force can either bend the
terminal post internally or result in internal cracking of the insulator.
To avoid plug damage the following qualities are required in a wrench (See Figure 2);

1. That it fits the spark plug "hex" properly.

2. The inner space must be large enough to avoid contact with the insulator.
3. The spark plug socket must completely cover the "hex" portion of the metal shell.
4. A hexagonal socket is preferable as it is less likely to slip than a twelve point star type.

11 : Examples of problems caused by excessively over long periods of use

Deposits accumulated on the firing end may induce abnormal combustion (pre-ignition), causing
problems that include melting of the electrodes.
Good

Worn Electrodes

If the edges of electrodes are worn and rounded, sparks will not easily occur, which lead
engine starting problems and mis-firing during running: maximum power cannot be
obtained from the engine.

Fouled

Power leaks through the carbon accumulated on the firing end, causing mis-firing as wel
hindering engine starting.

Deposits

The deposits accumulated on the spark plug overheat and cause abnormal combustion (p
ignition) that may lead to melting of the electrodes of the spark plug.

Why is the firing end appearance of a spark plug important?

Because the Firing end appearance reflects the suitability of the spark plug as well as the
condition of the engine. There are three basic criteria: good, fouled, and overheated. The firing
end appearance also depends on the spark plug tip temperature.

The boarder-line between the fouling and optimum operating regions (450 degrees Celsius) is
called the spark plug self cleaning temperature. It is at this temperature that the deposits
accumulated are burnt off.
What is spark plug fouling?
It is a phenomenon by which carbon attached to the firing end causes electrical leakage that leads
to mis-firing.
As the high voltage generated by the ignition coil leaks away through the carbon, mis-firing may
occur and cause running and starting difficulties.

What is spark plug overheating?

Prolonged overheating may induce abnormal combustion (pre-ignition), resulting in melting of

the spark plug electrodes.
Overheated spark plugs have a white insulator surface at the firing end speckled deposits.
Electrode melting represents excessive overheating. When the spark plug temperature exceeds
870C, the firing end serves as a heat source before sparking and induces abnormal combustion
(pre-ignition), possibly damaging the piston.

Causes of overheating and corrective actions

Causes

Corrective actions

Ignition timing too far advanced

==>

Adjustment of ignition timing is required.

Air/fuel mixture(A/F) too lean

==>

Adjustment of air fuel ratio (A/f) is required.

Insufficient cooling water and lubricants

==>

Top up cooling water and lubricants

Applied turbo boost pressure too high in the case of a

==>
turbo engine

Adjustment of turbo boost pressure control is requir

Insufficient tightening of spark plug

==>

Tighten to specified torque

Use of too hot a spark plug

==>

Use colder spark plug

(Example: BK R5E-11 --> BK R6E-11)

What is lead fouling?

Lead deposits accumulated on the spark plug firing end help electricity to leak away and result in
mis-firing.
When the lead contained in gasoline as an octane enhancer, adheres as the firing end of the spark
plug, the high voltage generated by the ignition leaks through the lead deposits and causes misfiring during acceleration. This problem often takes 2,000 ~ 3,000 km (1,200 ~ 1,800 miles) to
become apparent.

Insulation resistance of a spark plug vs. vehicle speed.

Lead fouling does not appear during starting or low speed running. On the other hand, mis-firing
occurs when accelerating from the middle speed range since the insulation resistance of the spark
plug drops quickly.

Better selection of spark plugs.

Use hotter type (Example: BP6ES - BP5ES)
Use projected insulator nose type (Example: B6ES - BP6ES)