SuzukiSavage.com - &(^*^!#^$% timing cover

Sandy Koocanusa

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&(^*^!#^$% timing cover
06/06/08 at 12:13:10

I finally worked up a big enough set to tackle the valve inspection. I got all my tools handy and started to remove the seat. Then I got to thinking... It would be the pits to get the spark plug out and then not be able to remove this fancy timing inspection plug I've heard so many good things about. So I tried it. Sure enough, it is stuck solid.

I tried a washer, which promptly bent. So I sandwiched a washer between two others with their edges ground flat, and it bent. I know I just read a thread about this the other day, but I can't find it, and I don't know if anything was resolved anyway.

By the way, the plug on the parts bike came right out, which does me no good. But at least I'm sure it can be done.

So, once again... What to do now?

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Savage: (adj)1. Wild 2. Uncivilized : Primitive 3. Ferocious 4. Cruel or merciless : Brutal --- Webster's. (n.) 1. A motorcycle named for its seat.--- Sandy's unabridged

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youzguyz Serious Thumper Offline Posts: 2538 San Antonio, Texas Gender:	*Re: &(^^!#^$% timing cover Reply #1 -** 06/06/08 at 12:34:42 Check with your local motorcycle place for a Timing Plug Wrench.. like this Timing Plug Wrench You can also do a search through the forums for Timing Plug.. others have had luck with various work arounds.
Back to top	2002 - Silver (Thumper) 2000 - Green (Mad Hamish) Most motorcycle problems are caused by the nut between the seat and the handlebars. Make sure yours isn't too tight or too loose. IP Logged

Serowbot YaBB Moderator ModSquad Offline OK.... so what's the speed of dark? Posts: 28648 Tucson Az Gender:	*Re: &(^^!#^$% timing cover Reply #2 -** 06/06/08 at 12:41:26 Why o' why can't they make those things take an allen wrench!? Well,... first make sure and get some penetrating oil in there, then see if you have a butter knife with a decent curve on the blade (they're usually made of stiffer stuff than washers), then get a vice grip on it and pray. good luck
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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	*Re: &(^^!#^$% timing cover Reply #3 -** 06/06/08 at 12:48:37 This one worked for me, but didn't do it until after my plug looked like sh!t. Take 2 big same length screw drivers and a cresant wrench. Place the screwdrivers in the slot as far apart and still can be grabbed by the cresant wrench. Hold the handles with one hand and twist with the cresant wrench.
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Sandy Koocanusa

Serious Thumper

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Don't blame me.
I didn't vote
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Posts: 1878
Bigfork, MT
Gender: male

Re: &(^*^!#^$% timing cover
Reply #4 - 06/06/08 at 12:58:17

Thanks for all the replies. I got it.

I took a 1" spade bit (those flat wood boring bits for any non-carpenter types) and ground the end into a slight curve. Put a channel lock on it and gave my best caveman grunt. It came out. When it started to move, it felt like the resistance was in the rubber O-ring instead of the threads. Don't ask how I'd know that. It was just the impression I got. Guess I won't tighten it much when I put it back in.

Now on to the scary part. The valves.

Thanks again

Jason.

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Savage: (adj)1. Wild 2. Uncivilized : Primitive 3. Ferocious 4. Cruel or merciless : Brutal --- Webster's. (n.) 1. A motorcycle named for its seat.--- Sandy's unabridged

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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28884 L.A. California Gender:	*Re: &(^^!#^$% timing cover Reply #5 -** 06/06/08 at 13:07:46 Hmmm, those can be gotten rather cheaply, I'll put that in the memmory bank, thanks.
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Gary On A Savage Serious Thumper Alliance Member Offline Only 15 mins riding could save you $$$ in Dr bills Posts: 941 Fresno, California Gender:	*Re: &(^^!#^$% timing cover Reply #6 - 06/06/08 at 13:11:43 verslagen1 wrote on 06/06/08 at 13:07:46:** Hmmm, those can be gotten rather cheaply, I'll put that in the memmory bank, thanks. Yeah..and fits in the tool pouch! Not bad at all!
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Sandy Koocanusa Serious Thumper Offline Don't blame me. I didn't vote for him. Posts: 1878 Bigfork, MT Gender:	*Re: &(^^!#^$% timing cover Reply #7 -** 06/06/08 at 13:21:31 Yep. This one was part of a zillion part bit set that Costco had on sale a few years back for about $30. The box they came in was worth every penny, too. 1/2 the bits are stamped "Made in ina" The "Ch" guy must not have come to work that day. Anyway, the bit set just paid for itself. Finally.
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shermeco Junior Member Offline SuzukiSavage.com Rocks! Posts: 65	*Re: &(^^!#^$% timing cover Reply #8 -** 06/06/08 at 14:44:09 I got a really big screwdriver from harbor freight worked great!
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Sandy Koocanusa

Serious Thumper

Offline

Don't blame me.
I didn't vote
for him.

Posts: 1878
Bigfork, MT
Gender: male

Re: &(^*^!#^$% timing cover
Reply #9 - 06/06/08 at 17:57:53

Well, the job is done! Yay for my team! I'm glad I went and checked them too, because I couldn't get a 2 mil feeler gauge in them when I started. Now they are all at 3 1/2 - 4 mil.

It wasn't painful at all, but tedious. I'd get them set, tighten the nut, and they'd be too loose, then too tight. And I think my feelers were built for a bigger working space. It's pretty tight in there. Oh well, now I have one less thing to worry about on the way to Philipsburgh.

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Savage: (adj)1. Wild 2. Uncivilized : Primitive 3. Ferocious 4. Cruel or merciless : Brutal --- Webster's. (n.) 1. A motorcycle named for its seat.--- Sandy's unabridged

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Reelthing Serious Thumper Alliance Member Offline Fish or ride that is the question Posts: 5397 Houston,Tx Gender:	*Re: &(^^!#^$% timing cover Reply #10 -** 06/06/08 at 18:13:06 .003-.004 inch right ?
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Sandy Koocanusa Serious Thumper Offline Don't blame me. I didn't vote for him. Posts: 1878 Bigfork, MT Gender:	*Re: &(^^!#^$% timing cover Reply #11 -** 06/06/08 at 18:22:10 Yup. Sorry. Sometimes the carpenter in me leaks out.
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Reelthing Serious Thumper Alliance Member Offline Fish or ride that is the question Posts: 5397 Houston,Tx Gender:	*Re: &(^^!#^$% timing cover Reply #12 -** 06/06/08 at 18:46:00 of course 3-4 mils is correct also - was just looking for clarity - no idea how often these valves get set to say .012 " instead of .012 mm - folks that have done this sure report the engine clicks a little bit
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	*Re: &(^^!#^$% timing cover Reply #13 -** 06/07/08 at 01:07:21 The washer I use is so thick it barely fits in the groove & is large enough that I have to file the thing down to fit the curve of the groove. In Other words, It Fits the Slot very nicely. A washer 1/16th thick aint the answer, even if ya do make a steel sammich widditt.
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	*Re: &(^^!#^$% timing cover Reply #14 -** 06/07/08 at 01:10:45 OHHHH Yea, After all the "My timing cover wont come out" threads, I went & checked. Mine came right out & Yea, I DO give it that little extra after it stops, BUT,, mine is all slimey with antisieze, so the aluminum threads never get a chance to gall onto the mating threads.
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