SuzukiSavage.com - how can i take this off?

renegade1 Full Member Offline SAVAGE Posts: 212 Abbotsford B.C. Gender:	how can i take this off? 08/23/12 at 09:23:45 this darn thing just wont loosen, mind you i dont have a proper tool anyone have a part number so i can get one?
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Paraquat Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 2206	Re: how can i take this off? Reply #1 - 08/23/12 at 09:32:04 Digger took a large fender washer and ground it down until it would fit in. Some members use a Harbor Freight pry bar. Clymer's says to use a Honda tool and lists their part number. I had a piece of 1/8 flat stock I put a hole in so I could pry off of it. --Steve
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DangRider

Ex Member

Re: how can i take this off?
Reply #2 - 08/23/12 at 09:44:04

I was able to get it off by pressing the chisel end of a pry bar into the groove and clamping onto the bar with vise grips to turn the bar. I got behind the bar and leaned into it with my body weight to keep good purchase on the groove.

I also purchased a replacement cap that has a 10 mm allen socket so I don't have to fight that battle again.

Part number: 09259-36008 (at powersportsplus.com)

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28890 L.A. California Gender:	Re: how can i take this off? Reply #3 - 08/23/12 at 09:47:52 many ways... http://suzukisavage.com/cgi-bin/YaBB.pl?num=1327616086
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wambr Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 610 Russia, Samara Gender:	Re: how can i take this off? Reply #4 - 08/24/12 at 00:31:34 a long time I was tormented with the darn thing. in the end I had to drain the oil from the engine and remove the right crankase cover . then a good shed the threaded part of kerosene. only after such procedures managed to remove the darn cap...
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: how can i take this off? Reply #5 - 08/24/12 at 06:25:35 Thats what happens when people who do not understand mechanical things touch them. No need to crank that thing in like its a head bolt. Feel the threads stop, & give a light twist. It has an O-ring, its not gonna leak, Antisieze is your friend.
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running-it-stock

YaBB Newbies

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SuzukiSavage.com
Rocks!

Posts: 27

Re: how can i take this off?
Reply #6 - 08/24/12 at 08:44:51

renegade1 wrote on 08/23/12 at 09:23:45:

this darn thing just wont loosen, mind you i dont have a proper tool anyone have a part number so i can get one?

I am having the same problem. The specified tool is BikeMaster Timing Cover Plug Wrench 04-073 http://www.powersportsuperstore.com/BikeMaster-Timing-Cover-Plug-Wrench-04-07... which is equivalent to MotionPro's tool (08-0087). The key to opening it is use something the exact (3/16") width as the slot before you strip it, and the tool won't provide you that. Verslays idea of using the brake pads is the best fit I found.

You can also let the engine run, then put ice on the plug to contract it Wink

. Haven't tried it yet.
Also if you are looking for TDC take the spark plug out and use the electric starter or roll the bike to move piston.

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wambr Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 610 Russia, Samara Gender:	Re: how can i take this off? Reply #7 - 08/24/12 at 09:10:56 running-it-stock wrote on 08/24/12 at 08:44:51: Also if you are looking for TDC take the spark plug out and use the electric starter or roll the bike to move piston. the first time I did. trying to "catch" TDC in the compression stroke, turning the engine from the starter and watching the valves.
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SaVaGeEaRL Full Member Offline SuzukiSavage.com Rocks! Posts: 106 Georgetown, KY Gender:	Re: how can i take this off? Reply #8 - 08/24/12 at 11:03:58 the back of an old savage brake pad and a pair of vise grips to hold/twist works well
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RC Junior Member Offline SuzukiSavage.com Rocks! Posts: 83 Quartz Hill Ca. Gender:	Re: how can i take this off? Reply #9 - 08/24/12 at 21:27:16 The one dollar option is the old style U.S. dollar the ones the size of the old silver dollars of my youth. Don't use a real silver one its worth more than the tools you can buy, but if you have one of the later sandwich dollars from the 70s it will work great.
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wambr Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 610 Russia, Samara Gender:	Re: how can i take this off? Reply #10 - 08/24/12 at 23:47:01 SaVaGeEaRL wrote on 08/24/12 at 11:03:58: the back of an old savage brake pad and a pair of vise grips to hold/twist works well I tried to use them, but I did not remove the darn thing...
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justin_o_guy2

Serious Thumper

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What happened?

Posts: 55279
East Texas, 1/2 dallas/la.

Re: how can i take this off?
Reply #11 - 08/24/12 at 23:55:21

Pressure, or, straight torque, has less effect than impact. Build a tool with an arm on it, so someone can seat it in the slot & you can spank on it. Time spent making the tool fit the groove is time well spent,
Read everything you can on making it let go. A light "spanking" is a good idea. A pin punch & a Very Light hammer applied with NOthing More than a quick wrist that Does Not follow thru, to drive the metal back & rebuilding the edge of the groove is a good plan,

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The people never give up their liberties but under some delusion.- Edmund Burke.

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wambr Serious Thumper Offline SuzukiSavage.com Rocks! Posts: 610 Russia, Samara Gender:	Re: how can i take this off? Reply #12 - 08/25/12 at 22:36:30 thanks, JOG 2! now I already from the twisted this cap. this is not a problem for me now. just in the future I will not pull her so tight
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Cavie Full Member Offline My wife made me do it Posts: 107 Port charlotte Fl Gender:	Re: how can i take this off? Reply #13 - 08/26/12 at 05:51:24 http://www.toolsource.com/inch-square-drive-hand-impact-tool-p-67905.html?gcl...
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HondaLavis Senior Member Offline It's nothing personal; the other one came first. Posts: 451 Plano, TX	Re: how can i take this off? Reply #14 - 08/26/12 at 08:45:26 I have a HF chisel set, and the large chisel fits in the slot perfectly. The body of the chisel is 6 sided and a 12mm wrench ( or somewhere around there) fits perfectly. Take it off gently and you don't need to gorilla torque the thing when you put it back on.
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