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General Category >> Rubber Side Down! >> Timing port cover not going back on...
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Message started by AlphaBarney on 09/19/11 at 20:25:06

Title: Timing port cover not going back on...
Post by AlphaBarney on 09/19/11 at 20:25:06

Feeling like a real idiot with this one...so I just put my Verslavy in. It was easy and quick, and is looking much better. Fantastic! I wish my story ended there.
While I was waiting for the part I decided to adjust the valves and solenoid while the bike was on the lift. That part actually went okay, everything sounds better, and rides well. There was a little bogging at first, but it seems to have worked it's wat out as it warmed up
Of all the things that could go wrong the problem is that timing port cover wont go back on. I tried to be easy on it, because I thought I was cross threading it, but that wasn't it. Checked for any metal shavings in the threads, nope. It seems like the outer threads were marred by the offset wrench when I was trying to rotate the engine to TDC...as a noob it took quite a few attempts before I got it right.
I was able to get the port cover started just a bit, but then it wouldn't budge. I pried it on as best I could, but it is still sitting off from the case quite a bit, nowhere near flush.
Trying to find out my best options for this one...am I screwed?
I was going to buy a replacement port cover for a Volusia that I saw on here that uses a hex wrench. But now I'm afraid I'm going to have to buy a whole new engine casing. Is there any hope for this case/cover? Can I rethread the port somehow?

Also, is it rideable in this condition? If it isn't sealed I dont want to be getting junk in the engine...

Title: Re: Timing port cover not going back on...
Post by justin_o_guy2 on 09/19/11 at 20:43:06

If you HAVE to ride, cover it with duct tape, Id build a tool & back it out, study the threads in the case & on the plug, solve that problem, study threads & line up start threads to install it, Isnt there an oring in that thing? Make sure its seated, if so. Dont Crank it tight, snug only, its a real pain to remove if it gets Landed too hard.

I Would use the tape,, those threads are pretty fine & its most likely not gonna get the smallest piece of dust in it.

Title: Re: Timing port cover not going back on...
Post by verslagen1 on 09/19/11 at 21:02:18

As you explain it, you've mared the internal threads.

take some scotch brite and debur the threads.

Title: Re: Timing port cover not going back on...
Post by Serowbot on 09/19/11 at 22:23:04

I think duct tape is gonna' blow right off...
You gotta' get those threads working...

Title: Re: Timing port cover not going back on...
Post by justin_o_guy2 on 09/19/11 at 22:34:19

I agree,, it wouldnt be a long term thing, but if I HAD to ride a few miles to work,, thats how Id go at it, IF I couldnt fix the threads in time,, but getting those threads right is simply a Must Git 'Er Done" thing.

Title: Re: Timing port cover not going back on...
Post by AlphaBarney on 09/20/11 at 01:57:42

Thanks all, not a must ride at all. I'll give the scotch brite a try tonight and take a better look at it after work. Here's to hoping.

Title: Re: Timing port cover not going back on...
Post by drums1 on 09/20/11 at 05:04:49

Not to mention the oil that would be leaking out there. Mine leaks with the cover tight and a supposed new o-ring. I doubt that duct tape would hold.

Title: Re: Timing port cover not going back on...
Post by justin_o_guy2 on 09/20/11 at 07:28:59

A 90 degree scribe sharpened to a flat edge running across the tip mite work to drag the threads into place.

Title: Re: Timing port cover not going back on...
Post by MotoBuddha on 09/20/11 at 10:20:49

You could get the version of the cover made for the C50. It has an Allen wrench socket instead of a slot. With everything cleaned and lubed, you can crank that puppy in there.

http://i280.photobucket.com/albums/kk182/motobuddha/dded9c56.jpg

Title: Re: Timing port cover not going back on...
Post by AlphaBarney on 09/20/11 at 13:58:54

That's the one I was thinking of! You don't happen to know the part number for that off hand do you? I suppose my lazy butt could look that up pretty easily if you don't.

Title: Re: Timing port cover not going back on...
Post by Bubba on 09/21/11 at 08:16:14

Part # 09259-36008

I picked one up at one of the shops I go to. It was cheaper to have them order it then to get it shipped.

Title: Re: Timing port cover not going back on...
Post by Bubba on 09/21/11 at 08:17:37

first ya gotta get the threads in line tho' otherwise the new part won't help :(

Title: Re: Timing port cover not going back on...
Post by AlphaBarney on 09/21/11 at 17:09:24

Just updating...so what happened was that the outer-most groove on the stator cover got bent over into the next thread. Just took a sharpened flat head screw driver and carved it back out being careful to not get any metal inside the case. It's tougher to get the plug on/off now, but it's fully seated again. Took it for a short ride, just to heat up the oil, no leaks, so I think it's better for now.
For what it's worth I found out that the small flat blade on the side of a painter's multitool works REALLY well to loosen/tighten the plug. Too bad I marred mine all up before I figured this out. Will be replacing with the C50 part this weekend.