Crankcase Cover Plug

[New GZ250]

Just had the dealer perform the 600 mile service, to make a long story short they really screwed up my crank cover plug. Instead of hassling with them I ordered a new plug. When I go to replace the plug will I have to be careful that a ton of oil will flow out. Or as I think and hope there is no oil behind that plug. (I'm talking about the plug on the left side of the engine case, about an 1 1/2 " in diameter.)

Thanks in advance!

[kaput]

I think you are referring to what the manual calls the "generator cover cap" and it is not very oily. There is oil there but it is not going to drip everywhere.

How much did you pay for the new cap? Mine is pretty messed up too but I did it myself, I think there may be a special tool for it. You may want to look into getting that tool before you replace it.

Good luck.

[New GZ250]

I think you are referring to what the manual calls the "generator cover cap" and it is not very oily. There is oil their but it is not going to drip everywhere.

How much did you pay for the new cap? Mine is pretty messed up too but I did it myself, I think there may be a special tool for it. You may want to look into getting that tool before you replace it.

Good luck.

The cap, I believe is to cover the crank, as I think they opened it to adjust the valves. (To find top dead center) This has a one inch slit about 1/8 wide which is about an inch long. It is p/n 09259-36011. (Thanks to our part list) Cost less than $20.00 from BikeBandit delivered. It is the only cap in the center of the engine cover on the left side. (Ankle high) I got it loose being '"somewhat" careful as it is really messed up, with scratches and aluminum burrs. In fact to the point my hiking boots are wearing through, the more I shift and rub against it. Since it is a new bike, I assume it was really torqued down when assembled and the mechanic tore into it! :??:

[kaput]

Yes, that is the generator cover cap. Easy to mess up with the wrong tool and over torques easily. Like I said, mine is messed up from me opening it with a vice grip on a silver dollar which was the only way I could figure to open it unless you have a HUGE SCREWDRIVER, but my bike is not new at all so I don't care so much. Again, look into that special tool.

If it is wearing through your boots it is way worse than mine, mine's just scratched and ugly.

Don't worry about oil at all, very minimal.

[New GZ250]

Yes, that is the generator cover cap. Easy to mess up with the wrong tool and over torques easily. Like I said, mine is messed up from me opening it with a vice grip on a silver dollar which was the only way I could figure to open it unless you have a HUGE SCREWDRIVER, but my bike is not new at all so I don't care so much. Again, look into that special tool.

Don't worry about oil at all, very minimal.

Hope you didn't ruin the "silver" dollar as it is probably worth more than the plug!
:)

[bonehead]

There are specialty screwdriver bits that fit on 3/8 drive ratchets. Probably won't find them at H/Depot or Lowes. I got mine off the Snap-On truck years ago. They work great for the covers.

[cspan37421]

I'd love any tips on how to either find that specialty bit (where do you go to find the Snap-On truck? Do they play a jingle while driving through your neighborhood? :)

I've tried very hard to get the cover cap off and no luck. Large coins and odd tools - such as the one on this page:

http://i2kdave.wordpress.com/2009/07/23 ... djustment/ (http://i2kdave.wordpress.com/2009/07/23/motorcycle-valve-adjustment/)

I did try both WD40 and Liquid Wrench to loosen it up. Not a whiff of luck.

I have an impact wrench, but the bits are nowhere near the right size for the cap slot.

[bonehead]

Keep an eye out around the garages and car dealerships in the area. they call on them, based on their route at least once a week. Same goes for Cornwell and Matco. Might even try yellow pages for tool stores in your area. Hell, look at Sears, they might even have it. On line tool companies should have it too. Try KD tools, Delegard tools, S-K tools, etc.... Good luck.

[bonehead]

Just found the #'s for the socket. Snap on #GF22(on their website). And I called a fried who has the one I borrowed, it is a P&C 6076.

[cspan37421]

Thanks for the lead on Snap-On - it looks like you can order from their website?

I might stop at my dealer tomorrow and see what they use. I also know the manager at the local Precision Tune - he rides motorcycles too, and I imagine he uses something. If I can't get much going there, I'll probably try to order the snap-on one.

BTW, I tried the walking the bike in gear and peeking in the sight hole for the TDC indicator. My bike would not walk in gear - low gear or high. The tires actually skidded on my garage floor. Maybe my floor is too smooth....

[Easy Rider]

The tires actually skidded on my garage floor. Maybe my floor is too smooth....

High gear should work better. Hope it is the floor that is too smooth and not the TIRES. :shocked:

At least it shows that you have good compression. That should work a LOT better if you remove the spark plug !!

[cspan37421]

My Suzuki dealer's service department guy said he made the tool himself - welded a small, flat steel plate to a bit that could be put in an impact screwdriver or wrench. I can't weld, so forget that idea.

On the Snap-On GF22, what does it mount into? It's not clear from the website. At first I assumed it went in a 3/8 drive socket wrench, but it doesn't actually say that - nor does it look like it does.

[bonehead]

3/8 drive ratchet.

[alantf]

I can't weld, so forget that idea.



Why do you need to weld? A local repair shop or even the guy who told you about it should be able to weld it for you, for not many $$$$$$$. :)

[cspan37421]

Just an update - earlier this week the GF22 drag link socket from Snap On came in and I bought it from the local snap-on truck. I didn't get to try it out until today, but I did, and it both fit well and did the job. It still took a LOT to move the cap, and when it did, it had a give as it some seal had broken. The thing was truly stuck! But the GF22 does fit the slot well (as some have noted, it's maybe more important to fit the width of the slot than the full length - the GF22 does not fit the entire length but it fits enough to turn it.

[Water Warrior 2]

Makes me wonder how it was turned in that tight. Luckily you were able to get it out without anything getting broken or destroyed. And now there is a quite expensive tool in your tool box. I have a few myself, never needed them after the first use and too valuable to toss out.

[steelpix]

This should work from Sears. Just less then 1 inch long.

Socket Drag link from Sears.

http://www.craftsman.com/craftsman-15-1 ... 944513000P (http://www.craftsman.com/craftsman-15-16-in-socket-drag-link/p-00944513000P)

[Water Warrior 2]

This should work from Sears. Just less then 1 inch long.

Socket Drag link from Sears.

http://www.craftsman.com/craftsman-15-1 ... 944513000P (http://www.craftsman.com/craftsman-15-16-in-socket-drag-link/p-00944513000P)
Okay, I just have to ask. How and when would you use this tool? I need an example to relate to so it doesn't just look like a very expensive screwdriver bit.

[blaine]

This should work from Sears. Just less then 1 inch long.

Socket Drag link from Sears.

http://www.craftsman.com/craftsman-15-1 ... 944513000P (http://www.craftsman.com/craftsman-15-16-in-socket-drag-link/p-00944513000P)
Okay, I just have to ask. How and when would you use this tool? I need an example to relate to so it doesn't just look like a very expensive screwdriver bit.

Here ya go.

http://www.globalsoftware-inc.com/coole ... 40/21C.htm (http://www.globalsoftware-inc.com/coolerman/fj40/21C.htm)

;) :)

[JohnC]

Yeah, but...
The slot in the cover plug is rounded. the correct washer is the perfect tool and the price is right, too. Weld it to a cheap socket if you must get fancy.

[raul10141964]

I use this
http://s23.postimg.org/4znt905x3/Camera_ZOOM_20130921124709945.jpg (http://postimg.org/image/4znt905x3/)

[Water Warrior 2]

Thank you Blaine.

[blaine]

Thank you Blaine.

;) :)