Now that I've managed to destroy the intended method of removing the magneto cover on my '99 Suzuki DR650, what are my options for removing the little cover?
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obviously you need to order a new one immediately. If you are anywhere near McKinney (north Dallas) come to my house (with the new one so we can fit it afterwards) and I will take it out for you!!
Otherwise I would be drilling 2 small holes in the plug and then putting screws in those holes, put a bar between the 2 screws and try rotating (unscrewing) the cover!!
Gary
I had the same problem one time and used a cold chisel with a sharp flat blade on it and put it on the outside area and whacked it several times.
Carl, I had that same problem when it was mine. Or maybe I helped some else remove theirs and I was careful with mine. But yes, order a new one first because that one will be useless after you get it off.
What I did is look at where the threads were on the new one and drilled two holes in the cover far enough in to not hit the threads of the case. Then I put in two pins and used a bar between them to turn the cover. A couple of screws for pins would work fine and a long screwdriver. And looking at that cover and how shiny it is, I'm betting it was that bike I fixed.
Fastest way to fix your problem is to replace the '99 DR with an '18 KTM 500
Take some pictures of the cure to share with others afflicted with the same problem. Turning the rear wheel and trying to align the timing mark is a pitb. I'll be using anti seize if I ever decide to replace mine.
Now that I've managed to destroy the intended method of removing the magneto cover on my '99 Suzuki DR650, what are my options for removing the little cover?
All excellent and proven extraction methods. Thank you. Is there any use in applying a bit of Liquid Wrench before attempting any of the extraction methods?
...I can get a stuck cover plug out faster then it took me to type this response no heat or chemicals involved ...
I feel ya. Since I have a drill and punch set, and no chisel set, looks like that might be the method to try first.
http://www.sears.com/craftsman-5-pc...ew/p-00966202000P?sid=SLIAx106x101x1071909965
http://www.sears.com/craftsman-6-pc...ew/p-00952156000P?sid=SLIAx106x101x1071909965
This might work if you can get it to bite???
I'm guessing it didn't seep into any of the threads to loosen them up. Good luck.
Attempted four types of removal today, but wasn't able to break the cover loose.
Attempt #1 was with a torx bit. All I managed to do was round out the hole some more. The metal seems very soft.
Attempt #2 was with a borrowed extractor. Same result as the torx bit. Just a larger hole.
Attempt #3 was drilling two holes and using a borrowed spanner wrench. The wrench fit well but slipped out as soon as a decent amount of pressure was applied. Maybe screws would hold better and then using a screwdriver might work.
Attempt #4 was to angle a punch, strike it to get the cover to loosen. You can see the angled hole in the picture above.
Will try to find suitable screws and try that method. Else I will remove the crank case cover and take it to the guys in the machine shop at work.