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General Category >> Rubber Side Down! >> Timing Plug Tool on-the-cheap
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Message started by DragBikeMike on 04/21/18 at 16:34:32

Title: Timing Plug Tool on-the-cheap
Post by DragBikeMike on 04/21/18 at 16:34:32

I tried to take my timing plug out. Knew it would be tight so I got a big old washer and filed it down a bit so it would just fit in the slot. I stuck a 3/8" extension through the hole and that bad boy washer folded up like a wet noodle. Don't try that. You gotta bite that washer as close as possible to the plug.

Here's a pic of what happens when you do it the wrong way:

Title: Re: Timing Plug Tool on-the-cheap
Post by DragBikeMike on 04/21/18 at 16:36:50

So I grabbed another washer out of my junk bin. A washer with a 2-1/2" OD works perfect. File it down until it just fits into the slot. It should be tight such that you have to tap it in with a small hammer.

Here's a pic of the filed down washer:

Title: Re: Timing Plug Tool on-the-cheap
Post by DragBikeMike on 04/21/18 at 16:38:54

Then grab that washer as close as you can to the plug. Not so close that you mar the finish on your case, but close enough to keep the bending moment on the washer to as low as reasonably achievable.

Here's a pic of the grab:

Title: Re: Timing Plug Tool on-the-cheap
Post by DragBikeMike on 04/21/18 at 16:39:53

Now give it a yank and pop that bad boy loose. Geeeeez! These things are tight.

Title: Re: Timing Plug Tool on-the-cheap
Post by verslagen1 on 04/21/18 at 16:47:21

think cheaper...
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1232437043
http://www.savageriders.com/verslagen/ValveAdj/DSCN0487.JPG

Title: Re: Timing Plug Tool on-the-cheap
Post by Serowbot on 04/21/18 at 16:53:41

..or get a plug for an S50... They take an allen wrench.
It will cost $10 though...

Worth it, if you plan on keeping the bike for while...

Title: Re: Timing Plug Tool on-the-cheap
Post by eau de sauvage on 04/21/18 at 17:09:20

The first time was a nightmare it was in so tight had to take it to a garage.

So the next time, I measured the maximum width before the slot curves up on the sides, which was 23mm I went to the local sheet metal cutter and they found a piece that was 2mm thick it could be a bit thicker maybe 5/64ths but this was enough. They sliced me a piece 23mm wide no charge. Used channel locks to grip it.

http://https://s31.postimg.cc/betyepouf/tool.jpg (https://postimg.cc/image/betyepouf/)

607364657A7771737827160 wrote:

think cheaper...
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1232437043
http://www.savageriders.com/verslagen/ValveAdj/DSCN0487.JPG

Yeah that'll work if the plug is ready to fall out, but if it's tightened up a bit, you're having a larf with that. Even if you use the tang that hold the tank on it will bend, as I found out.

Title: Re: Timing Plug Tool on-the-cheap
Post by justin_o_guy2 on 04/21/18 at 17:26:07

My
Fixing too tight
Tool is a piece of a lawnmower blade.
I'll probably never need it again.
Antisieze is your friend.

Title: Re: Timing Plug Tool on-the-cheap
Post by norm92de on 04/21/18 at 17:48:59

Of course when you put it back only tighten it a bit more than finger tight. Mine comes out without any problem at all. No leaks and no damage from tools trying to get it loose.

The Allen key solution sounds like a great idea.

Title: Re: Timing Plug Tool on-the-cheap
Post by Dave on 04/22/18 at 03:56:18

Yep........finger tight with your washer/brake pad/etc. it all you need.

Here are the part numbers for the cover that used the hex wrench. It comes in chrome or painted.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1416070003