SuzukiSavage.com - Removing the timing plug

DanGill Full Member Offline Posts: 222	Removing the timing plug 01/09/08 at 14:52:50 I have not been able to get the timing port plug off my '06 S40. I bought a large washer and ground the thickness to fit the slot snugly, then tried to turn it with vice grips and a crescent wrench. I bent the washer. Is there a trick to this? Cold engine? Warm engine and ice on the plug? A better tool?
Back to top	Swapped the S40 on a Shadow Spirit 1100 IP Logged

Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Removing the timing plug Reply #1 - 01/09/08 at 15:24:09 There are actually tools to do that. I do not recommend using a large screwdriver and hammer to turn it, but I have done it that way too. It will turn if you tap it that way, but you can scratch or crack the aluminum. This is the one that I have from Ron Ayers.
Back to top	IP Logged

rigidchop Serious Thumper Offline don't feed the drama llama Posts: 1105 ravenswood wv Gender:	Re: Removing the timing plug Reply #2 - 01/09/08 at 15:56:17 i used a metal ruler, and a crescent wrench, worked perfectly.
Back to top	87 VM ED L IP Logged

SteveRocket1 Senior Member Offline A day without riding is like a day without beer. Posts: 441 California Gender:	Re: Removing the timing plug Reply #3 - 01/09/08 at 16:14:35 I used a new cold chisel and a crescent wrench and it came off ok, but the correct tool is best to avoid damage Steve
Back to top	'87 Savage but now with a Supertrapp muffler with 8 disks and competition end cap, TKat Fork brace, oldfeller airfilter, Z Bars, Turn Signal bleeper,Rather Loud Horn. and cousin Bonnie too.. IP Logged

thumperclone Serious Thumper Alliance Member Offline PGR rider riding with respect Posts: 6047 Grand Junction Colorado Gender:	Re: Removing the timing plug Reply #4 - 01/09/08 at 17:02:05 some threads need a slight thighting b4 loosing..correct tool is always best..
Back to top	standing for those who stood for US IP Logged

T Mack 1 - FSO

Serious Thumper
Alliance Member

Offline

sold 2001 LS650 for
a 1986 XLH1100

Posts: 2919
Emmaus,Pa
Gender: male

Re: Removing the timing plug
Reply #5 - 01/09/08 at 17:55:58

WD-40/ CRC/ Liquid Wrench (pick one) the night before you want to work on it. Tap lightly after spraying to help work it in. Next day, clean the slot with degreaser or alcohol. Tap again , then try. Tighten tiny bit then loosen. It may be corroded so you may need to do the tighten loosen tighten loosen drill many times. Once it starts to move, don't force it too much. The back & forth method works , just need paitence.

Back to top

Engineers design things, Technicians make them work.
---
30% of being mechanical is confidence/30% is knowing to go slow when needed/30% is looking repeatedly at what you have/10% is dumb luck Wink

IP Logged

verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	Re: Removing the timing plug Reply #6 - 01/09/08 at 20:32:49 I don't think the lubes will work there's an o-ring. Get greg's tool if you want to get it off w/o damage. If you don't care, then 2 big screwdrivers with a little space inbetween and a cresent wrench. I tried the washer bit, worst than a screwdriver and hammer.
Back to top	Versey's Place Tech Section Index IP Logged

Savage_Greg

Serious Thumper
Alliance Member

Offline

Don't go around your
ass to reach your
elbow...

Posts: 7844
SW Washington State
Gender: male

Re: Removing the timing plug
Reply #7 - 01/09/08 at 22:53:52

Honestly, I used a large screwdriver as a "drift punch" for years, until one day I cracked the plug in the process. Couldn't even see the crack because it was in the slot. When I was done, I put it back together (a friend's bike too) and everything seemed just fine...that is until he called me from his house to tell me about the oil leak on his way home.

After that I made one but it kept bending and would slip. So finally I bought one. Funny too, the wrench costs just about the same as a new plug...about $15.

It ain't easy learning how to be a "Handyman" Tongue

Back to top

IP Logged

DanGill Full Member Offline Posts: 222	Re: Removing the timing plug Reply #8 - 01/10/08 at 06:43:51 Thanks, I'll get the tool. Fortunately, the washer didn't bugger up the slot. It just didn't get the job done. I'll use some liquid wrench first, too.
Back to top	Swapped the S40 on a Shadow Spirit 1100 IP Logged

Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Removing the timing plug Reply #9 - 01/10/08 at 08:34:11 DanGill wrote on 01/10/08 at 06:43:51: Thanks, I'll get the tool. Fortunately, the washer didn't bugger up the slot. It just didn't get the job done. I'll use some liquid wrench first, too. BTW - the tool has 3 different sizes on it, so if you get another bike (Heaven forbid), it'll work there too.
Back to top	IP Logged

DanGill

Full Member

Offline

Posts: 222

Re: Removing the timing plug
Reply #10 - 01/10/08 at 11:44:12

Savage_Greg wrote on 01/10/08 at 08:34:11:

DanGill wrote on 01/10/08 at 06:43:51:

Thanks, I'll get the tool. Fortunately, the washer didn't bugger up the slot. It just didn't get the job done. I'll use some liquid wrench first, too.

BTW - the tool has 3 different sizes on it, so if you get another bike (Heaven forbid), it'll work there too.

Saw that. Actually, I had so much trouble turning it, that I was not sure the proper tool would do the job. Right now I'm off my feet following arthroscopic knee surgery. Back aboard soon.

Back to top

Swapped the S40 on a Shadow Spirit 1100

IP Logged

Savage_Greg

Serious Thumper
Alliance Member

Offline

Don't go around your
ass to reach your
elbow...

Posts: 7844
SW Washington State
Gender: male

Re: Removing the timing plug
Reply #11 - 01/10/08 at 20:03:53

DanGill wrote on 01/10/08 at 11:44:12:

Savage_Greg wrote on 01/10/08 at 08:34:11:

DanGill wrote on 01/10/08 at 06:43:51:

Thanks, I'll get the tool. Fortunately, the washer didn't bugger up the slot. It just didn't get the job done. I'll use some liquid wrench first, too.

BTW - the tool has 3 different sizes on it, so if you get another bike (Heaven forbid), it'll work there too.

Saw that. Actually, I had so much trouble turning it, that I was not sure the proper tool would do the job. Right now I'm off my feet following arthroscopic knee surgery. Back aboard soon.

Ouch! I had arthroscopic shoulder surgery almost 2 years ago. I got that one...I "felt" your pain, so to speak. That really cramped both my riding and wrenching for well over 6 months. Take it easy on the knee, at least I didn't need a shoulder to walk. Roll Eyes

Back to top

IP Logged

justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Removing the timing plug Reply #12 - 01/12/08 at 22:46:50 I found a large washer & ground it to fit the slot, ran a long bolt thru, with a washer on each side. I had to grind on the washers to relieve them enough so they didnt interfere with the main washer going in the slot. That "Backed up" the washer near the load & at the hole, it doesnt bend.
Back to top	The people never give up their liberties but under some delusion.- Edmund Burke. IP Logged

Savage_Greg Serious Thumper Alliance Member Offline Don't go around your ass to reach your elbow... Posts: 7844 SW Washington State Gender:	Re: Removing the timing plug Reply #13 - 01/13/08 at 06:01:18 I made this tool a long time ago, but it still was able to bend on some really tight plugs. I used some scraps of aluminum that I had laying around.
Back to top	IP Logged

DanGill

Full Member

Offline

Posts: 222

Re: Removing the timing plug
Reply #14 - 01/25/08 at 06:08:20

I got the MotionPro wrench, and the large blade was too thick to fit into the slot. I ground the sides of it down a bit, but it still seemed like it wasn't going into the slot all the way. I ended up using a hammer and large screwdriver to drift the plug loose, then turned it out with the next smaller blade. When I re-checked the valves I was able to use the medium blade to open the plug and re-seat it.

It seems like none of the blades really fits well. But it'll do.

Back to top

Swapped the S40 on a Shadow Spirit 1100

IP Logged