SuzukiSavage.com - decompressor assembly& crank inspect. cover help

Graven754 Junior Member Offline SuzukiSavage.com Rocks! Posts: 56	decompressor assembly& crank inspect. cover help 04/24/16 at 17:30:52 So We ended up tearing up the cable for my automatic decompressor. How important is this cable? It's nnot snapped in half just unraveled a little. I could possibly solder if back together and it hold but not sure how that will affect performance. Also we can't get this crank case inspection plug off. Any pointers?
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Graven754 Junior Member Offline SuzukiSavage.com Rocks! Posts: 56	Re: decompressor assembly& crank inspect. cover he Reply #1 - 04/24/16 at 17:31:52 This is the decompressor assembly. I'm not near my bike right now but this a picture before the cable go broke.
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justin_o_guy2

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Re: decompressor assembly& crank inspect. cover he
Reply #2 - 04/24/16 at 18:09:06

I ran a bolt through a coupla fat washers, hit the grinder, shaping them to fit the radius,and hit it with some Real penetrating oil, not WD 40, and got it out. Use antisieze going back together.
Crud accumulates around the spark plug. Clean out before removing it.
Antisieze on the plug. It's good stuff. Steel bolts in aluminum, just a dab helps a lot.

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Graven754

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Re: decompressor assembly& crank inspect. cover he
Reply #3 - 04/24/16 at 18:24:34

justin_o_guy2 wrote on 04/24/16 at 18:09:06:

I ran a bolt through a coupla fat washers, hit the grinder, shaping them to fit the radius,and hit it with some Real penetrating oil, not WD 40, and got it out. Use antisieze going back together.
Crud accumulates around the spark plug. Clean out before removing it.
Antisieze on the plug. It's good stuff. Steel bolts in aluminum, just a dab helps a lot.

Do you have a picture of what you threw together in order to get it off?
that would be so helpful. If you don't have it, maybe a drawing.

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engineer

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Re: decompressor assembly& crank inspect. cover he
Reply #4 - 04/24/16 at 18:32:51

I found a metal backing plate for an old brake pad that was a perfect thickness for the slot on the plug and like JOG shaped it with a bench grinder to make a tool for plug removal.

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So We ended up tearing up the cable for my automatic decompressor. How important is this cable?

Well the cable is important in that it operates the decompressor. The picture doesn't show how badly it is damaged but if it is still functioning and the strands are still intact and not too badly frayed then it will probably continue to operate for some time. However, I like to correct my mistakes so I would probably replace the cable.

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2005 S40, Intruder shocks, Dyna, 52.5/150, 3 washers, 2 turns, modified seat, Raptor

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justin_o_guy2

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Re: decompressor assembly& crank inspect. cove
Reply #5 - 04/24/16 at 18:40:00

I sold the bike and the parts and special tools went with it.
I'm not an artist.
Two washers, or one really thick one, that fit nicely in the slot.
A bolt, two nuts. If you need to, use more washers, and, once you have it fitting, solder it up. Or, wait, see if you need to solder it. Like plywood, layers of metal, joined by glue,are stronger than the sum of the parts. A propane torch or Mapp gas torch will get it.
Before you solder, grind the washers to fit in the slot, if you grab the right diameter, you won't have to grind.

So, put a nut and small washer, ( yes, I am adding stuff I just remembered ) on the bolt, put the washers on that will fit in the slot, and another small washer, and another nut. Tighten up.

Holding the tool firmly in the slot with some torque on it, tapping with a small hammer can be good.

I didn't solder. The bolt was about four inches. It wasn't very stuck. We have seen some jammed so badly that they were destroyed getting them out. A replacement with a Phat allen wrench drive is available.
Watch the edges and try not to booger them up.

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verslagen1

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Re: decompressor assembly& crank inspect. cove
Reply #6 - 04/24/16 at 19:56:17

Here's a thread on the timing cover tool...

http://suzukisavage.com/cgi-bin/YaBB.pl?num=1232437043

Key to getting the job done is finding a piece on metal that fits in the slot tightly.
A hard piece is best, but if you turn it with a good sized crescent wrench held tight to the case, even a soft piece will do.
In a pinch the seat support on the back end of the tank will do. but you might have to straighten it afterwards.

take a plastic hammer and give the port a good smack.
this won't make it any easier, but may break loose any corrosion locking the cover to the case.

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Versey's Place
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verslagen1 YaBB Moderator ModSquad Online Where there's a will, I want to be in it. Posts: 28886 L.A. California Gender:	Re: decompressor assembly& crank inspect. cover he Reply #7 - 04/24/16 at 20:03:45 You can start the bike without the decompressor, but it might stall. when it does stall, you have to bump the engine over the compression stroke. 2nd or higher and bump forward. if you have an pre 95, going backward can break starter teeth or worse.
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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: decompressor assembly& crank inspect. cover he Reply #8 - 04/24/16 at 20:08:56 You can replace the stock cover with one from a Marauder that uses a large Allen wrench to loosen it. It's easier to use than a slot.
Back to top	There's no problem that a full tank of gas and a sunny day can't fix! 2008 S40, Rotella T 15W-40 w/ZDDP added, Dyna, 140/90-15, Battery Tender Jr., Seat lift, #52.5/150/3 washers, Raptor IP Logged

DesertRat Serious Thumper Offline I love rat bikes! Posts: 1569 Arizona	Re: decompressor assembly& crank inspect. cove Reply #9 - 04/24/16 at 21:32:17 Kris01 wrote on 04/24/16 at 20:08:56: You can replace the stock cover with one from a Marauder that uses a large Allen wrench to loosen it. It's easier to use than a slot. Which Marauder? Year? Model? the 2004 VZ800 Marauder microfiche show a SLOTTED cover ...
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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 18101 Camp Springs, Kentucky Gender:	Re: decompressor assembly& crank inspect. cover he Reply #10 - 04/25/16 at 04:03:36 You want chrome.....or painted? http://suzukisavage.com/cgi-bin/YaBB.pl?num=1416070003
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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: decompressor assembly& crank inspect. cover he Reply #11 - 04/25/16 at 05:15:22 You don't get that good a service at Whataburger.
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Kris01 Serious Thumper Offline Eat, sleep, RIDE! Posts: 3767 Tennessee Gender:	Re: decompressor assembly& crank inspect. cover he Reply #12 - 04/25/16 at 19:51:43 You crack me up JOG!
Back to top	There's no problem that a full tank of gas and a sunny day can't fix! 2008 S40, Rotella T 15W-40 w/ZDDP added, Dyna, 140/90-15, Battery Tender Jr., Seat lift, #52.5/150/3 washers, Raptor IP Logged

justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: decompressor assembly& crank inspect. cover he Reply #13 - 04/26/16 at 05:29:45 Yeah, I amaze myself. I am a study in conflict. I'm either making them laugh or making them mad. But, seriously, it's Free, and people just fall all over themselves trying to Help others. I just enjoy this place.
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jrobeson18 Full Member Offline Jeep and a Suzuki, how can i lose? Posts: 121 Charlotte NC Gender:	Re: decompressor assembly& crank inspect. cover he Reply #14 - 04/26/16 at 08:37:09 haha, so true. this place is nice. wish there were people who have done write ups for certain things for the inexperienced and scared. (me). JOG2- you are funny, lol
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