I just ran into this problem myself after overtightening this plug on my last valve adjustment. I tried the gasket scraper tool from harbor freight with wrench and a perfect fitting washer on a vice grip to no avail. I even attached a 2 foot and 3 foot pole to each one of these contraptions and all I ended doing is badly stripping this plug. Finally I got some sense and did a lot of research. I ended up heating the plug with a blow dryer on high for 2 minutes, blasting it with computer cleaner upside d..own and tapping it with a punch and hammer. It ca out it no time. I replaced it with the plug from a vl800 which fit like a glove.

FlyingH wrote on 09/18/20 at 17:57:31:


You can look in the Technical Section and find all kind of useful things:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1181745927

Here is the thread about the timing cover:
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1416070003

Serowbot lists the part numbers for the chrome and painted versions.
In the second post I showed what the painted version looks like before I stripped the paint and buffed the aluminum.

FlyingH wrote on 09/19/20 at 06:15:04:


There is only one bolt on big brake kit that I know of.  I bumped it back up to the top of the Marketplace section.
http://suzukisavage.com/cgi-bin/YaBB.pl?board=market

From memory I think the Boulevard M80 uses the same size timing cover with a hex hole instead of a slot.