|
SuzukiSavage.com
/cgi-bin/YaBB.pl General Category >> Rubber Side Down! >> Removing valve timing inspection cover advice /cgi-bin/YaBB.pl?num=1416177122 Message started by Philmh on 11/16/14 at 14:32:02 |
|
Title: Removing valve timing inspection cover advice Post by Philmh on 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! |
|
Title: Re: Removing valve timing inspection cover advice Post by Yoshi on 11/16/14 at 14:37:51 I've got mine off with a big washer (not too thick) in a vice grip |
|
Title: Re: Removing valve timing inspection cover advice Post by Demin on 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. |
|
Title: Re: Removing valve timing inspection cover advice Post by verslagen1 on 11/16/14 at 14:45:22 http://suzukisavage.com/cgi-bin/YaBB.pl?num=1232437043 |
|
Title: Re: Removing valve timing inspection cover advice Post by HighME32 on 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. |
|
Title: Re: Removing valve timing inspection cover advice Post by Kris01 on 11/16/14 at 19:06:40 Where did you find it? |
|
Title: Re: Removing valve timing inspection cover advice Post by HighME32 on 11/17/14 at 08:00:33 Where did i find what? The cover? At the dealer. |
|
Title: Re: Removing valve timing inspection cover advice Post by Philmh on 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. |
|
Title: Re: Removing valve timing inspection cover advice Post by verslagen1 on 11/17/14 at 14:58:23 1A22232627224A0 wrote:
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. |
|
Title: Re: Removing valve timing inspection cover advice Post by Steve H on 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. |
|
Title: Re: Removing valve timing inspection cover advice Post by Philmh on 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. |
|
Title: Re: Removing valve timing inspection cover advice Post by verslagen1 on 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. |
|
Title: Re: Removing valve timing inspection cover advice Post by Gowor on 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. |
|
Title: Re: Removing valve timing inspection cover advice Post by Dave on 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. |
|
Title: Re: Removing valve timing inspection cover advice Post by justin_o_guy2 on 11/18/14 at 15:55:26 Antisieze, get some. |
|
Title: Re: Removing valve timing inspection cover advice Post by Philmh on 12/02/14 at 12:17:30 So I bought the parts from the dealer and am currently waiting on them to arrive with baited breath. I sprung for the hex cover that may, or may not fit. It is non-returnable and took considerable amount of time at the parts counter to locate. While I waited, I compared my cover to all of the Suzuki's on hand and noticed the covers matched in diameter but was unable to determine if the threads matched as well. Once the parts come in, if the part fits, I will repost the details. Fingers crossed. ;D |
|
Title: Re: Removing valve timing inspection cover advice Post by Philmh on 12/04/14 at 13:56:42 Parts came in! Ran right into the garage and sure enough..... HighMe32 is on to something..... THE PLUG FIT!!!! For all looking to do the same Suzuki Part # 09259-36008 It is chromed, but really doesn't stand out :D :D :D :D :D :D :D :D |
|
Title: Re: Removing valve timing inspection cover advice Post by Dave on 12/05/14 at 03:39:19 625A5B5E5F5A320 wrote:
I thought it was chrome. I ordered one from a DR650 that appears to be the same - but is painted, it is part number 09259-36016-20H, and it was $ 8.76. If it fits, I can strip the paint and polish the aluminum to match. I will let you know when it arrives if it works or not. |
|
Title: Re: Removing valve timing inspection cover advice Post by Art Webb on 12/05/14 at 09:06:11 this info should be stickied, so anyone who wrecks their cover can find it easily |
|
Title: Re: Removing valve timing inspection cover advice Post by Serowbot on 12/05/14 at 09:26:13 27343231232424460 wrote:
It's in the Tech Section... (I just updated it to include the dr650 version)... ;)... http://suzukisavage.com/cgi-bin/YaBB.pl?num=1416070003/0#0 -Serow |
|
Title: Re: Removing valve timing inspection cover advice Post by Art Webb on 12/06/14 at 08:12:33 Well, don't I look dumb, thanks Serowbot |
|
Title: Re: Removing valve timing inspection cover advice Post by Serowbot on 12/06/14 at 08:24:27 Not at all... and it creates a good opportunity to point out the link to others... :)... |
|
Title: Re: Removing valve timing inspection cover advice Post by KY Bluegrass on 06/03/18 at 17:47:08 Since mine is seriously tight and none of the jerry rigs worked, I decided to hunt. Found the actual designated tool for $15 on Amazon It is called a Motion Pro 08-0087 Timing Plug Wrench Ordered it, hope it works. Sigh. https://www.amazon.com/gp/product/B000GTTOMA/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1 |
|
Title: Re: Removing valve timing inspection cover advice Post by eau de sauvage on 06/06/18 at 04:51:26 Apparently the plug from the M50 boulevard fits and it has a hex hole. Why the frack they didn't just use that on the S40 is beyond my ability to fathom. |
|
Title: Re: Removing valve timing inspection cover advice Post by Surviving Philly on 12/02/23 at 20:01:46 Reviving this thread looking for some ideas: I destroyed the slot on my timing plug port, and I'm struggling to get it removed. For those curious, earlier in this threat there is an aftermarket plug wrench listed, that DOES NOT fit the stock sized timing port. This is the actual correct OEM part, which is actually a honda part: honda "07709-0010001" The clymer book lists the wrong number. As you can see, this thing costs over 60 bucks. I've also already destroyed by plug and did buy a new one that accepts a hex. Any ideas on how to remove a destroyed stock plug? |
|
Title: Re: Removing valve timing inspection cover advice Post by verslagen1 on 12/02/23 at 20:32:11 A lot of hopin' and prayin' and cussin' The problem is caused by forcing 2 similar metals together and they bond or weld together. Crush that o-ring until the plug seats on the cover and this is what you get. Hit the plug with a hammer, tap it around the edge. You're not trying to break it, just upset the bond a bit. Squirt it with pen oil. Then what you need is some stiff metal that fits the slot tightly, a used front brake pad fits the bill nicely. You can even reshape it a bit and it makes a nice wrench. Gently tap the metal into the slot till you feel it bottom. Get a big cresant wrench (remember you're not askin') place it on the pad and in contact with the cover, adjust it tightly and turn it as best you can w/out it camming out. If it didn't come out, go ask a sailor for some new words. ;D BTW, replace that dam o-ring when the plug seats or it'll happen again. |
|
Title: Re: Removing valve timing inspection cover advice Post by Surviving Philly on 12/02/23 at 22:10:01 Thanks Vers, I'll take a heat gun and pen oil/ hammer to it, try to see if I can upset that cold weld. If not I suppose I'll take it off try to wedge a chisel in there see if I can twist the entire thing out. |
|
Title: Re: Removing valve timing inspection cover advice Post by Yoshi on 12/03/23 at 03:47:51 I just removed my stuck cover without destroying it, I first used a heat gun to get the cap real hot then I used a punch and a hammer to spin it to the left, surprisingly I didn't mess up the cap or the motor cover. The reason my cap was real stuck was because the o-ring melted itself to the cases threads. Now I need a new o-ring |
|
Title: Re: Removing valve timing inspection cover advice Post by Dave on 12/03/23 at 13:09:31 And remember folks......just snug them up when you put them back in. They don't wiggle loose - the O-ring keeps them from backing out. |
|
Title: Re: Removing valve timing inspection cover advice Post by ThumperPaul on 12/04/23 at 06:05:39 I’m sure Dave is 100% right about “just snug it”, but I’m personally the master of over tightening especially when it comes to o-rings intended to seal (in my mind, they are like crush washers). Just can’t trust “tight enough”. And when they have big arse specialized tools for the job, it just screams at you to crank that sucker in there tight!! I’m on my 3rd S40/Savage and every one has come with that sucker driven in there seized up tight (so I know I’m not alone)! Thanks for the tip and post bump about the upgraded plugs (c50 and dr650). I’ve done a lot of reading on the forum, but good info can be elusive sometimes. Like Justin O said, I now reinstall with a bit of anti-seize. And even knowing Dave’s tip, I know I will still probably over tighten and kill the o-ring. I did make a tool out of a 1” drill bit by cutting off the sharp tip and filing it down. It works, but I have to be careful not to push and hammer with it and let it do its job (turning). That said, I will be buying an upgrade with an Allen. |
|
Title: Re: Removing valve timing inspection cover advice Post by Surviving Philly on 12/09/23 at 11:31:28 So -- For anyone that comes across this thread. DO NOT chisel into the timing port cover while it's mounted. I was trying to wedge a used brake pad into the cover, actually punched though the timing plug (with a rubber mallet, mind you). Now I have debris in there and will need to pull the alternator cover. For those in the know -- does the drive shaft pulley need to be removed to disconnect the wire for the alternator? Or am I'm I good just to pull the cover? Thanks |
|
Title: Re: Removing valve timing inspection cover advice Post by ThumperPaul on 12/09/23 at 12:53:19 The alternator wires running along the engine case and up to the frame to the regulator should be trapped behind a small retaining plate and screw that is just to the upper right of the pulley (as you look at the bike from the left side). After that, they run up the frame and are held with reusable zip ties. You should just be able to detach the wires at the regulator. Sorry about the timing cover plug! I've done the same thing. It was a tiny chip that knocked off in there. I just left it in there and hoped it wouldn't travel elsewhere. I rode that bike another 1000 miles or so and never heard from it. But, don't trust my stupid ways. I'm the guy that breaks off dowel rods in the spark plug hole and into the cylinder! |
|
SuzukiSavage.com » Powered by YaBB 2.2! YaBB © 2000-2007. All Rights Reserved. |