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Help! Question about head plug! (Read 95 times)

mscepu101 Full Member Offline SuzukiSavage.com Rocks! Posts: 104	Help! Question about head plug! 05/13/13 at 17:42:46 I just started the head plug job tonight. It took an hour to remove the tank and the lines but I was being cautious! I need to know if I need to put the engine at TDC. I ask this question because I cannot get the cover off the side of the engine to gain access to the 17 mm nut and timing mark. I would appreciate any advise!
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Re: Help! Question about head plug!
Reply #1 - 05/13/13 at 18:02:29

You don't need to have the engine at TDC - but it has to be at a place where the cam is not lifting any of the valves before you try and remove the head cover. You could take the valve inspection caps off to see when that is.....and put the engine in gear and roll the bike to move the crank. (Not the way I would recommend).

Someday I will be old......But not today!

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mscepu101 Full Member Offline SuzukiSavage.com Rocks! Posts: 104	Re: Help! Question about head plug! Reply #2 - 05/13/13 at 18:30:32 Any advise how to remove the cover over the 17 mm nut?
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Re: Help! Question about head plug!
Reply #3 - 05/13/13 at 18:37:55

There is this thread posted a couple of days ago.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1368244667

I made a tool using some 1/8" thick steel. One fellow uses an old disc brake pad...the metal end. Another fellow uses a flat washer he ground to a shape that fits the slot. There have been several people post about this issue......Have you looked in the technical section about replacing the plug????? There should be something in that thread about the cap.

OK....Verslagen uses the brake pad.

Someday I will be old......But not today!

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28889 L.A. California Gender:	Re: Help! Question about head plug! Reply #4 - 05/13/13 at 18:44:40 hmmmmm... Take your hat off? Is this the timing inspection port? yes? use the newly discovered seat hold down plate. don't bend it.
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mscepu101

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Re: Help! Question about head plug!
Reply #5 - 05/14/13 at 16:34:09

SEAT HOLD DOWN PLATE WORKED!!!

I did bend it though...just a little...

Removing the head was tricky. It was not a straight lift and slide to one side. It required some thinking.

I notice the head plug was just laying in the hole. Not even a friction fit! And no RTV. It was the old style.

I will set the new plug after dinner and start again tomorrow night. I hope all goes well!

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Boofer Serious Thumper Offline Nearly too old. Posts: 1760 N Ms Gender:	Re: Help! Question about head plug! Reply #6 - 05/14/13 at 21:27:42 I took a 3/4 inch cold chisel and tapped it lightly in the groove; then pushed in with my hand and turned like a screwdriver with a set of ViseGrips. Worked for me. "Any tool can be the right tool." Red Green
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