My Auto-Lite 4164 bottom plug solution

All other motorcycle related topics go in here." However, DO NOT post ANY messages that are related to politics or religion in here. They will be erased. Thanks!

Moderator: Moderators

Post Reply
mad1150
Basic User
Posts: 418
Joined: Fri Nov 03, 2006 2:52 pm
Donating Member #: 522
Location: La Moille, IL

My Auto-Lite 4164 bottom plug solution

Post by mad1150 »

As everyone here probably knows, or may find out the hard way, the Auto-Lite 4164’s are a replacement for the bottom plugs on the twin-spark models. However, they won’t fit in the standard BMW plug wrench and to make matters worse, a standard 11/16” deep socket that fits the plug will not fit up into the plug well of the engine.

One solution would be to buy a thin-walled socket, but I found them to cost $20.00 or more and that seemed a little steep to me. So, as I stated at the end of another post, in a fit of rage I went to the nearest auto parts store and bought a cheap 11/16” deep socket and ground it down on my bench grinder till it fit. After all, I would only be out $5.00 if it didn’t work.

It’s not pretty, but it worked:
Image

Up close:
Image

As you can see it was pretty crude. And due to the out of roundness I thought at the time, it was sticking inside the well a bit. But, I didn’t want to grind on it anymore because it was starting to get pretty thin.

Well, the possibility of having a socket get stuck in the engine wasn’t sitting well with me so just before Christmas I picked up another socket. I took it to a friend who’s in charge of the Tool & Die Dept. where I work, along with my crude attempt & the BMW tool, and explained what I needed. In about 10 minutes he showed up in my cube with this “BMW Quality” version:
Image

Up close:
Image

Holding my crude version, He said: “You ground this down on a bench grinder?”
I said: “Yeah, why?
He said: “I measured it and it’s nearly perfectly round! You may have a second calling!”

There you have it, my simple low-cost solution to the Auto-Lite 4164 problem! Well, as long as your pretty good with a bench grinder, have a lathe, or a Tool & Die guy handy anyway.
Mark - Member 522

04 R1150R (Silver)
User avatar
stilldking
Double Lifer
Posts: 131
Joined: Wed Oct 24, 2007 5:06 am
Donating Member #: 594
Location: NoDak
Contact:

Re: My Auto-Lite 4164 bottom plug solution

Post by stilldking »

That's a nice solution...

I was wondering if I could get the measurements, outside diameter and how far down/up the socket you ground for clearance.

Thanks
John C.
John C
There are 10 kinds of people in the world, those that understand binary and those that don't.
mad1150
Basic User
Posts: 418
Joined: Fri Nov 03, 2006 2:52 pm
Donating Member #: 522
Location: La Moille, IL

Re: My Auto-Lite 4164 bottom plug solution

Post by mad1150 »

No problem:

1- Duracraft Pro 11/16" CR-V, 3" long, 1/2" drive, Deep Socket (appx $5.00)

Modification Dimensions: Turned down to a diameter of .850" for 1" from the socket end.


FYI: The one I ground down measures .858" dia. at it's widest and was only ground down for appx. 5/8". And, the BMW socket measures .849 dia. at it's widest and is fluted for about 5/8". I had them turn an inch off in case I needed it for something else. Of course when that happens, I'll need a different size #-o
Mark - Member 522

04 R1150R (Silver)
User avatar
stilldking
Double Lifer
Posts: 131
Joined: Wed Oct 24, 2007 5:06 am
Donating Member #: 594
Location: NoDak
Contact:

Re: My Auto-Lite 4164 bottom plug solution

Post by stilldking »

Thanks Mark,
I'll see about getting one of these modified by the local machine shop. (They do good work and charge next to nothing.)

Thanks again!
JC
John C
There are 10 kinds of people in the world, those that understand binary and those that don't.
Buckster
Lifer
Posts: 1189
Joined: Sat Mar 17, 2007 12:53 pm
Donating Member #: 543
Location: Richmond, VA

Re: My Auto-Lite 4164 bottom plug solution

Post by Buckster »

Very nice and thanks for sharing. Probably a stupid question but, is this problem just for the twin spark Bottom plugs? I have a single spark and have not changed my plugs myself yet. I didn't know if I would need to do the same mod or not.
Buckster '03R
#543
mad1150
Basic User
Posts: 418
Joined: Fri Nov 03, 2006 2:52 pm
Donating Member #: 522
Location: La Moille, IL

Re: My Auto-Lite 4164 bottom plug solution

Post by mad1150 »

Buckster,

This is specifically for using Auto-Lite 4164's as the replacements for the bottom plugs on twin spark models. The 4164's are available at most local auto parts stores where the Bosch YR6LDE replacements had to be ordered.

The plug wrench that came in the BMW tool kit will work on the top plugs. In fact it's required because of how deep they are in the cylinder.
Mark - Member 522

04 R1150R (Silver)
mad1150
Basic User
Posts: 418
Joined: Fri Nov 03, 2006 2:52 pm
Donating Member #: 522
Location: La Moille, IL

Re: My Auto-Lite 4164 bottom plug solution

Post by mad1150 »

Buckster,

This is specifically for using Auto-Lite 4164's as the replacements for the bottom plugs on twin spark models. The 4164's are available at most local auto parts stores where the Bosch YR6LDE replacements had to be ordered.

The plug wrench that came in the BMW tool kit will work on the top plugs. In fact it's required because of how deep they are in the cylinder.
Mark - Member 522

04 R1150R (Silver)
User avatar
priapismic
Basic User
Posts: 333
Joined: Mon May 16, 2005 6:01 pm
Donating Member #: 0
Location: Mayberry, NE Texas

Re: My Auto-Lite 4164 bottom plug solution

Post by priapismic »

Good tip, Mark. Wish I had thought of something like that last spring when I found out that tightening the Autloite secondary plug with vice grips (couldn't find a workable socket to fit) resulted in this:

Image

Pretty nasty, eh? The plug loosened up and eventually fell out before I had a chance to tighten it up properly. Here's some more damage:

Image

Yup, even burned up the engine guards:

Image


Lesson learned (the hard way): get a proper wrench and tighten that bugger! Now I've got a stripped secondary plug hole, and though the wire has been "repaired" by a BMW shop, I won't feel right till it's replaced. And who knows what other damage I might've done - won't know that until the head is removed and I can see the valves and piston crown. Wish me luck ...
Viagra Donor and well-known reprobate and provocateur ....
User avatar
towerworker
Lifer
Posts: 2356
Joined: Sun Jan 08, 2006 8:11 pm
Donating Member #: 575
Location: Staunton Virginia

Re: My Auto-Lite 4164 bottom plug solution

Post by towerworker »

Here is what I think is a better alternative to using the 4164 Autolites for the secondary plug. I have been running the 3923's as primary's with good results for the past year. Just installed my second set last week. I seriously considered using the 4164's and bought a set but the issue of the plug wrench stopped me. I considered having one turned down but thought that not a good alternative just to use the 4164.

NGK's website: http://www.ngksparkplugs.com/ Provides some useful information concerning plugs

The NGK DCPR6E is the NGK recommended plug for the secondary in the 1150. Fits the BMW plug wrench just like the 3923 and is $2.29 each at Advance Auto. Their part number is 3481.

I installed a set of secondary's today and ran probably 200 miles. Ran fine. I could tell no difference between the Bosch oem's and the NGK's in terms of starting and performance. If you want to go a step higher and get platinum tipped you'll pay a buck or so more per plug. (Advance Auto) Still not a bad deal. The 3923's and the DCPR6E's seem to me to be a very good and inexpensive alternative for spark plugs for our machines. By the way NGK lists the plug gap at .032 (Primary) and .028 (secondary) and those numbers are for our bikes specifically. fwiw---I had already set mine at .034 on both and it ran fine. I may change them to the above gap numbers and check the difference.

Wayne
The Older I Get, The Less I know. (in honor of MikeCam
'05 RT
'04 R
'03 R
CB750
KZ750
HD 350 Sprint
mad1150
Basic User
Posts: 418
Joined: Fri Nov 03, 2006 2:52 pm
Donating Member #: 522
Location: La Moille, IL

Re: My Auto-Lite 4164 bottom plug solution

Post by mad1150 »

Cool!

Thanks for all the info Wayne!

I'll more than likely order a set of DCPR6E's next time I change them. No one had them in stock locally. Nearest "Adv. Auto" is an hour away. The pains of living in "Corn County IL" :roll:
Mark - Member 522

04 R1150R (Silver)
User avatar
towerworker
Lifer
Posts: 2356
Joined: Sun Jan 08, 2006 8:11 pm
Donating Member #: 575
Location: Staunton Virginia

Re: My Auto-Lite 4164 bottom plug solution

Post by towerworker »

Mark---I bet you could order online from their website--maybe get two or three sets to make it worth the shipping.

Wayne
The Older I Get, The Less I know. (in honor of MikeCam
'05 RT
'04 R
'03 R
CB750
KZ750
HD 350 Sprint
User avatar
Dr. Strangelove
Double Lifer
Posts: 1996
Joined: Sun Aug 07, 2005 2:40 pm
Location: #488Livin' in a Poor Man's Shangri.La

Re: My Auto-Lite 4164 bottom plug solution

Post by Dr. Strangelove »

thanks for the info. I found an NGK solution also. Found some at NAPA, but there, whichever ones I got, were $20 for the pair (platinum). That was over 12k miles ago and when last checked they were fine looking. But $3 a piece is better.

John
'09 Schwarze Blanche DuBois
Well, don't do that-Hippocrates
Post Reply