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

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

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

Looks like you need a shotgun.

No! No! just kidding.  

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.

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

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

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

Ahhhh.Now I see.