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Message started by dex3703 on 03/23/08 at 15:52:45

Title: problem adjusting valves
Post by dex3703 on 03/23/08 at 15:52:45

Hi,

I'm attempting a valve adjustment for the first time and can't get the TDC bolt cover (the little cutout with the notch in the big generator (?) cover on the left side) to come off. How do you remove this?

I've been spraying it with PB Blaster and tapped it with a screwdriver to try to loosen it, and I think I broke out a piece of it inside the slot, which is now inside the case. I don't know for sure.

Can somebody tell me how to get this little cover off, or if I should just take the entire larger cover off, and confirm there's no sliver floating around inside? If I do this what do I have to watch out for?

I have the Suzuki shop manual but it's not the best. :(

Thanks in advance,
Derek

Title: Re: problem adjusting valves
Post by verslagen1 on 03/23/08 at 16:18:21

There is a tool for getting that off, search and you may find it in the TDC thread. Lools like a tire tool with end ground like a big screw driver.

Last time I used 2 screwdrivers, one to fill up the space and turned it with the other one. As I had put a new o-ring in it came off easily. The 1st time was a be otch. And yeah got a chip in the slot. You don't need to pound on them like an old screw. Maybe just put a piece of wood over it hit to break any corrosion. Shouldn't be any though, dam thing is oiled from the inside.

Some have said a big washer will break it loose but I don't think so. I have big ones and all they did was twist. maybe if you use the washers to take up space and keep from damaging the plug. 1 on each side of the biggest screwdriver you got. ;D hope this helps

Title: Re: problem adjusting valves
Post by dex3703 on 03/23/08 at 16:38:27

Thanks I'll look and see if I have a tire tool like that, I used to. I tried a washer and a quarter, turning it with pliers, but it just bent them.

Do I need to worry about the little bit of metal inside the slot I chipped out that fell inside? Anything else I need to know?

Thanks,
Derek

Title: Re: problem adjusting valves
Post by verslagen1 on 03/23/08 at 18:55:28

any bit of metal left to wander on it's own will find a place you don't want to be sooner or later. If in fact you did loose a piece of that plug, you better go in and get it.

another way is 2 screwdrivers as wide apart as will still fit in the jaws of a monkey wrench. Hold the screwdrivers steady and turn with the wrench. This most likely damage the slot a little, but since you've already done that might be the way to go.

Title: Re: problem adjusting valves
Post by Robertomoe on 03/23/08 at 19:12:24

didn't someone make a tool with a big angle iron like a bed rail?

Title: Re: problem adjusting valves
Post by dex3703 on 03/23/08 at 19:22:59

Thanks. I guess I need to replace that cover since oil blows out of it (I started it and ran it for about 10 seconds--hasn't been run since last September or so).

So I'll be needing:
- tool to get the thing off (tried various screwdrivers, chisels, other wide flat objects--don't work)
- new cover
- gasket for the larger cover

Anything else? I don't really want to ride it to a shop with the bit of metal floating around, so I might as well do this all next weekend. :(

Thanks,
Derek

Title: Re: problem adjusting valves
Post by verslagen1 on 03/23/08 at 22:27:38

Looks like you need a shotgun.

No! No! just kidding. ;D

Get 2 hammers, 2 big screwdrivers and a friend with timing.

You tap left side going down and he taps right side going up or vice versa.

Title: Re: problem adjusting valves
Post by Rockin_John on 03/23/08 at 23:47:27

If you can't find one of some regular brand like Craftsmanm, Mac or Proto to buy; you can buy an old 1/2" drive socket and have a weld shop make you a socket like this (or similar):

http://catoosatrading.com/images/slothead_socket.jpg

I've had that one since the 70s, and don't remember where I got it.

Title: Re: problem adjusting valves
Post by Oldfeller on 03/24/08 at 02:56:56

To help the coarsely threaded "O" ring tensioned large flat slotted aluminum timing cover insert to come out easier do this first.

Put a little light oil on it (a drop or two of motor oil would be fine) to help lubricate the initial motion of the "O" ring as it is in full compression "stiction" mode right now between the cover material and the round button material.

Next, take your small nylon face hammer (craftsman makes a good one, has nylon and rubber faces about the size of a normal hammer) and put a couple of mild light whacks right in the middle of the round insert. This compresses the coarse threaded engagement from one side of the thread clearance to the other and exercises a little bit of the oil you just put down on the outside of the round thingie to break up the "O" ring stiction a bit.

Now it will turn out fairly easily using your home made tool. Remember to put the round thingie back kinda mildly torqued when you put it back in. A bit of grease on the "O" ring and threads is helpful to keep the stiction monster away for next time.

Oldfeller

Title: Re: problem adjusting valves
Post by justin_o_guy2 on 03/24/08 at 04:34:19

By using other washers to sandwich the middle "drive" washer, you can build a tool that works. File/grind the washer to fit the curve of the slot. The fit the other 2 washers to the one that fits the slot, only get rid of the metal just along the edge that slips in the slot. Now, IF a guy drilled a few holes in the outer washers & had tthen welded up, the 3 washers would just be hard as heck to mess up. You could treat then , to make them tougher than just washers. Heat them up orangish & drop them in oil.
Sorry ya busted the plug, It IS just the plug, right? Not the whole sidecover?

Title: Re: problem adjusting valves
Post by dex3703 on 03/24/08 at 08:21:34

Thanks all for the suggestions.

- the tool. I have tried various items but none have worked so far. I'll go to Sears and see if I can find a big slotted thing like in the picture. At Lowes last night I did find a masonry chisel that looked like it might work, but it was too long. If it's not too expensive from Suzuki I'll just get theirs.

- I've sprayed the cover with PB Blaster and tapped with a hammer through a folded piece of cardboard. Thing still doesn't budge, at least with the normal tools I have.

- I broke out the piece of the center slot that fell inside by trying to tap at an angle with a screwdriver, trying to turn it off to break it.

- I don't really have a way to make tools, unfortunately.

Why didn't Suzuki make this with a normal bolt or nut you could remove with a wrench or socket? I hate this special tool required crap--one of the main drawbacks of american cars.

Well I'll call the Aurora Suzuki when they open and see what they say. Does anyone have any parts I should add to the list? Since this is looking like a bigger job, should I do anything besides adjust the valves? Bike is a 2001 (?) and has about 6000 miles on it.

Thanks,
Derek

Title: Re: problem adjusting valves
Post by vtail on 03/24/08 at 11:09:14

I use a large thick washer that fits nice inside the slot (available at Lowe's, Home Depot etc) clamped in a visegrip. Workes good without boogering the slot ;) KISS

Title: Re: problem adjusting valves
Post by demin on 03/24/08 at 12:20:13

I'm confused(nothing new ;D)If you broke off a piece of the inspection cover,how did it get inside the motor?

Title: Re: problem adjusting valves
Post by steely on 03/24/08 at 16:02:29

4A4B4347402E0 wrote:

I'm confused(nothing new ;D)If you broke off a piece of the inspection cover,how did it get inside the motor?

If I understand correctly (a very dubious proposition) ;), I believe that he punched the screwdriver through the slot and knocked a piece off of the inside of the inspection cover into the engine.

Title: Re: problem adjusting valves
Post by demin on 03/24/08 at 16:18:45

Ahhhh.Now I see. :-?

Title: Re: problem adjusting valves
Post by dex3703 on 03/24/08 at 17:12:17

Yes that's what happened.

The Suzuki place wasn't very helpful, but at least they have the parts in stock and they aren't expensive.

Title: Re: problem adjusting valves
Post by demin on 03/24/08 at 17:16:48

Most stealerships aren't.When you tell them Savage/S40 they look at you like you're from another planet :-?.I'm suprised they had the parts :o.

Title: Re: problem adjusting valves
Post by Rockin_John on 03/24/08 at 21:35:52

06071A51555251620 wrote:

Yes that's what happened.

The Suzuki place wasn't very helpful, but at least they have the parts in stock and they aren't expensive.

The part's guys at the dealerships are only supposed to be helpful in finding and selling you parts and accessories. Helping you beyond that puts their mechanics in the shop out of a job. You're not at Auto Zone with a quasi mechanic or shade tree hotrod guy behind the counter willing to give tips.

If your dealer actually stocks parts, that is a miracle in itself. They should be congratulated.

Title: Re: problem adjusting valves
Post by Toymaker on 03/25/08 at 04:25:38

I'm having thesame problem...getting the plugout. I know mine hasn't been removed in 13 years....I tried and broke a corner of the "slot" off. Then I tried the tapping screwdriver way...darned if I didn't crack the plug and it leaks oil BARELY. Now I have ordered another plug and until it comes I'll seal up the slot and I'll removed sealer when I remove plug in a destructive manner...I though about drilling two holes, opposite the slot and make a tool to remove the old plug. Does anyone know about how much clearence there is between the plug and the stuff behind it?

Title: Re: problem adjusting valves
Post by dex3703 on 03/30/08 at 08:59:48

Thanks folks. I finally got it off with a brake adjustment tool (has a nice long flat side). I removed the generator cover and fished all the metal bits out I can find and it looks like I got them all. Adjusted the valves and hopefully all is well. Will start it later today.