SuzukiSavage.com - Removing valve timing inspection cover advice

Philmh

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Removing valve timing inspection cover advice
11/16/14 at 14:32:02

So I finally set off to remove my headcover in hopes that the oil leaking is from the dreaded plug issue and now I am stuck attempting to remove my valve timing inspection cover in order to find TDC. Ive tried a nickel and a crescent wrench and the nickel sheared right off. I am assuming its a standard thread so I am rotating counter clockwise (towards the front of the bike) to no avail. Any advice would be helpful!

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Yoshi Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 880 LongIsland, N.Y. Gender:	Re: Removing valve timing inspection cover advice Reply #1 - 11/16/14 at 14:37:51 I've got mine off with a big washer (not too thick) in a vice grip
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Demin Serious Thumper Offline We need more chlorine in the gene pool Posts: 2435 Warren,Ohio Gender:	Re: Removing valve timing inspection cover advice Reply #2 - 11/16/14 at 14:38:04 I just used a big washer for about a half inch bolt.About 2" in diameter and a pair of vice grips.I saw one time somebody used the metal from a frnt brake pad.Yes it is regular(right hand) threads.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28996 L.A. California Gender:	Re: Removing valve timing inspection cover advice Reply #3 - 11/16/14 at 14:45:22 http://suzukisavage.com/cgi-bin/YaBB.pl?num=1232437043
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HighME32

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Re: Removing valve timing inspection cover advice
Reply #4 - 11/16/14 at 16:13:29

The gasket scraper from harbor freight works well too. I tried a rod and washer as well, but ended up over tightening it and it was impossible to take off. I took chunks off of the groove until i finally heated it with a blow dryer on hot and hit it with a punch. It came right out. After distroying the stock one, i bought a boulevard c50 (vl800) cover which was well worth it and has an allen wrench hole in it. That part is around 10-15 bucks.

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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: Removing valve timing inspection cover advice Reply #5 - 11/16/14 at 19:06:40 Where did you find it?
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HighME32 Junior Member Offline SuzukiSavage.com Rocks! Posts: 93	Re: Removing valve timing inspection cover advice Reply #6 - 11/17/14 at 08:00:33 Where did i find what? The cover? At the dealer.
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Philmh

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Re: Removing valve timing inspection cover advice
Reply #7 - 11/17/14 at 14:45:15

Thanks all for the great advice!

Unfortunately, that cover must have been put on by a herd of elephants as it didn't budge one bit with everything I attempted. I even ground down a steel flat bar that fit perfectly in the groove and it keeps skipping out of the groove. I left it with penetrating oil and took a rubber mallet to in in hope the vibrations will get the oil in and set up for when I get after work.

My last resort is figuring out a way to split it or drill it out and replace it with the hex head cover as suggested by HighME32

Any additional advice is warmly welcomed as I am going crazy trying to think of ideas to get it out.

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verslagen1

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Re: Removing valve timing inspection cover advice
Reply #8 - 11/17/14 at 14:58:23

Philmh wrote on 11/17/14 at 14:45:15:

My last resort is figuring out a way to split it or drill it out and replace it with the hex head cover as suggested by HighME32

If you have drill, I'd take the cover off or you'll have chips in the engine with easy way to pull them out.

What happens is people tighten it down too hard and over compress the o-ring so that the outer lip of the plug contacts the cover.

So, if you've got a replacement coming, I'd cut off the outer edge of the plug. Maybe someone will measure from the edge to the O-ring, if I don't. Cut that off and it should unscrew easy.

Hitting the plug with a hammer and a piece of wood worked for me and didn't destroy the plug.

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Steve H Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 1223 Spartanburg, SC Gender:	Re: Removing valve timing inspection cover advice Reply #9 - 11/17/14 at 16:58:51 I used a piece of a brake pad from a car. The metal was just the right thickness to fit the slot and the curve was perfect for a good fit. Pushed it in nice and tight and held it in while turning it with vise grips clamped onto one end of the pad.
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Philmh

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Re: Removing valve timing inspection cover advice
Reply #10 - 11/17/14 at 21:12:46

:'(. Well I went big today. I took the sidecover off, took a cold chisel to the groove and hammered it into the aluminum and punched it through until it was wedged tight. I then took my adjustable wrench to the chisel and turned it until the cover came loose. To say this was a Herculean effort is a little exaggeration but I definitely put some serious torque into removing this.

Lesson Learned..... This cover does not need to be tight to stay on.

Now to figure out the replacement that was suggested to me and hope all this effort fixes the oil leak.

Thanks to all.

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28996 L.A. California Gender:	Re: Removing valve timing inspection cover advice Reply #11 - 11/17/14 at 22:06:19 That o-ring will crush down and form to the recess. If you feel the plug bottoming out on the cover, back it off and put in a new o-ring.
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Gowor YaBB Newbies Offline SuzukiSavage.com Rocks! Posts: 21 Poland Gender:	Re: Removing valve timing inspection cover advice Reply #12 - 11/17/14 at 23:42:10 I use a mini-crowbar, like this one: http://www.neteberg.eu/en/crowbar-hultafors-108-mini.html. It gives a pretty long lever, and you can push it in with one hand, and rotate with the other.
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18314 Camp Springs, Kentucky Gender:	Re: Removing valve timing inspection cover advice Reply #13 - 11/18/14 at 03:30:22 And when you put this thing back on.....don't crank it down hard. Just turn it in until you feel it bottom out.....it only needs to be snug....not tight.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Removing valve timing inspection cover advice Reply #14 - 11/18/14 at 15:55:26 Antisieze, get some.
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