So I bought the parts from the dealer and am currently waiting on them to arrive with baited breath.  I sprung for the hex cover that may, or may not fit.  It is non-returnable and took considerable amount of time at the parts counter to locate.  While I waited, I compared my cover to all of the Suzuki's on hand and noticed the covers matched in diameter but was unable to determine if the threads matched as well.  

Once the parts come in, if the part fits, I will repost the details.  

Fingers crossed.

Philmh wrote on 12/04/14 at 13:56:42:


I thought it was chrome.  I ordered one from a DR650 that appears to be the same - but is painted, it is part number 09259-36016-20H, and it was $ 8.76.  If it fits, I can strip the paint and polish the aluminum to match.  I will let you know when it arrives if it works or not.

Art Webb wrote on 12/05/14 at 09:06:11:

It's in the Tech Section... (I just updated it to include the dr650 version)... ...
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1416070003/0#0
-Serow

Not at all... and it creates a good opportunity to point out the link to others...
...

Apparently the plug from the M50 boulevard fits and it has a hex hole. Why the frack they didn't just use that on the S40 is beyond my ability to fathom.

A lot of hopin' and prayin' and cussin'

The problem is caused by forcing 2 similar metals together and they bond or weld together.
Crush that o-ring until the plug seats on the cover and this is what you get.

Hit the plug with a hammer, tap it around the edge. You're not trying to break it, just upset the bond a bit. Squirt it with pen oil.
Then what you need is some stiff metal that fits the slot tightly, a used front brake pad fits the bill nicely.  You can even reshape it a bit and it makes a nice wrench.  Gently tap the metal into the slot till you feel it bottom.  Get a big cresant wrench (remember you're not askin') place it on the pad and in contact with the cover, adjust it tightly and turn it as best you can w/out it camming out.  If it didn't come out, go ask a sailor for some new words.  

BTW, replace that dam o-ring when the plug seats or it'll happen again.

I just removed my stuck cover without destroying it, I first used a heat gun to get the cap real hot then I used a punch and a hammer to spin it to the left, surprisingly I didn't mess up the cap or the motor cover.
The reason my cap was real stuck was because the o-ring melted itself to the cases threads.
Now I need a new o-ring

I’m sure Dave is 100% right about “just snug it”, but I’m personally the master of over tightening especially when it comes to o-rings intended to seal (in my mind, they are like crush washers).  Just can’t trust “tight enough”.  And when they have big arse specialized tools for the job, it just screams at you to crank that sucker in there tight!!  I’m on my 3rd S40/Savage and every one has come with that sucker driven in there seized up tight (so I know I’m not alone)!

Thanks for the tip and post bump about the upgraded plugs (c50 and dr650).  I’ve done a lot of reading on the forum, but good info can be elusive sometimes.

Like Justin O said, I now reinstall with a bit of anti-seize.  And even knowing Dave’s tip, I know I will still probably over tighten and kill the o-ring.

I did make a tool out of a 1” drill bit by cutting off the sharp tip and filing it down.  It works, but I have to be careful not to push and hammer with it and let it do its job (turning).  That said, I will be buying an upgrade with an Allen.