sv650s generator cover plug removal

[erik]

doing a bit of maintenance on the new bike, wanting to check the valve clearances before riding it much.

I had a bit of 'fun' trying to remove the generator cover plug from the LH crankcase side (it needs to be removed so you can turn the engine over with a socket on the end of the crank).
It's got a 10mm socket for an allen key in the plug. I couldn't move it with just an allen key, so used a bar to lever it, it stripped the hex shape in the plug! :argh:

<a href="http://i38.photobucket.com/albums/e118/edorp/sv650s/IMG_1186.jpg"><img src="http://i38.photobucket.com/albums/e118/edorp/sv650s/th_IMG_1186.jpg"></a>

I wasn't entirely sure the best way to overcome this problem, I didn't want to remove the side cover and disturb the gasket. I found a plate of aluminium and marked and drilled a hex pattern, then used the plate as a guide to drill holes in the plug (carefully to make sure I wasn't going right through or into the thread!). Then used a nail cut into bits for pins, stuck each pin in the drill and filed the end down so it'd slide into the holes in the plug, the rest of it was a press fit in the aluminium plate.

<a href="http://i38.photobucket.com/albums/e118/edorp/sv650s/IMG_1187.jpg"><img src="http://i38.photobucket.com/albums/e118/edorp/sv650s/th_IMG_1187.jpg"></a> <a href="http://i38.photobucket.com/albums/e118/edorp/sv650s/IMG_1188.jpg"><img src="http://i38.photobucket.com/albums/e118/edorp/sv650s/th_IMG_1188.jpg"></a> <a href="http://i38.photobucket.com/albums/e118/edorp/sv650s/IMG_1190.jpg"><img src="http://i38.photobucket.com/albums/e118/edorp/sv650s/th_IMG_1190.jpg"></a> <a href="http://i38.photobucket.com/albums/e118/edorp/sv650s/IMG_1191.jpg"><img src="http://i38.photobucket.com/albums/e118/edorp/sv650s/th_IMG_1191.jpg"></a>

I used a little bit of heat from a heat gun on the casing surrounding the plug, but don't know if it did anything. I didn't want to get carried away and damage the engine paint.

Anyway, I tapped the lever thing in place, then gently tapped it with a hammer and it worked! I got the plug out! :woohoo:

<a href="http://i38.photobucket.com/albums/e118/edorp/sv650s/IMG_1192.jpg"><img src="http://i38.photobucket.com/albums/e118/edorp/sv650s/th_IMG_1192.jpg"></a> <a href="http://i38.photobucket.com/albums/e118/edorp/sv650s/IMG_1194.jpg"><img src="http://i38.photobucket.com/albums/e118/edorp/sv650s/th_IMG_1194.jpg"></a>

It looks like there was locktite in there or something. The rubber o-ring was stuck to the casing like it was glued.

Anyway, it was a bit of a relief to get it out. :done:

[Pussy]

I removed one for a friend with a SV1000s just a few weeks ago. I bought a 3/8 drive 10mm impact hex socket to do the job. Get a new one, Erik, with a new "O" ring, and do it up to I think 8 ft/lbs... it's bugger all. Then you won't have any trouble next time

Edit: You did bloody well getting that one out! :niceone:

[erik]

I'll definitely be getting a new o-ring. I might have a go at fixing the old plug with durafix rather than getting a new one though. Just to see how it goes/if I can. It doesn't look like a new plug would be too expensive.