removing primary cover caps

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kevbo82

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Mar 12, 2012
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Hey guys,
just started working on my dad's 750, i took the primary cover off to change the fluids (gave it a decent polishing while it was off too) while i was polishing i went to take the caps out and using a rather large and manly flat head couldn't budge any but the level screw. Any trick to getting these off, and if they're this hard should i not try and just use a funnel and refill the primary through the level hole?
 
Use a big flat blade screw driver but instead of undoing it the nomal way lay the screw driver side ways and put the flat blade on the same angle as the slots and use the full levage of the screw driver to loosen the caps, I have been doing it this way for 36 years and have never had any troubles undoing them this way, the other way is to make up a speacial tool to slot into it firmly with a T handle.

Ashley
 
Wrench that came with my rear shocks works perfectly. Otherwise i'd grab some big washes from the hardware store and use a pliers.
 
Ashley,
just tried to sideways flathead method and it worked like a charm! thanks for the tip!
 
Maybe with the perfect screwdriver it can work but I have a chunk broken off my cap when I tried that a long time ago. There is usually a guy on ebay selling a homemade nice tool with close to the right curve welded to some 1/2" hex stock. I had to reshape it slightly on a belt sander but this works for me. There are other probably better (= more expensive) ones available too. It is easy to make if you can weld and cut metal. Bwolfie ?
 
yeah it certainly didn't see like the most graceful way of doing things, but it did work without putting much pressure into it so i was okay trying it. Upper black eddy eh! i'm 10 mins south of there in pipersville
 
A tappet wrench (spanner) works perfectly.

removing primary cover caps


Dave
69S
 
I use a big fat 2.5" washer ground down a bit for fuller fit in the big slots and smaller thinner washer for the thin one. I have one adjustable wrench end ground down for this too. There can be times on the road one might want to look in and the washers are most compact tool I know that won't bugger the slots if resistant. There is a factory tool of course. I wouldn't never use a screw driver - ugh - any more...
 
soak it in hot water, then try.

Righty tighty, lefty loosey.

The spanner is a good idea, thanks for that Dave.
 
i should mention when i tried the sideways screwdriver it was with the cover off the bike laying flat on a work bench. not so sure how great it would be on the bike...
 
I found somethign in the garage that fit the gap. My old caps were really screwed up, I know its because P.O.'s use screwdrivers and stuff and are not careful about it. I just made sure the piece of steel I found fit the gap closely.
 
I have been using the large screw driver trick for 36 yeas now without any problems, its like anything you do on your bike just take it easy and be care full of what you do, as for the spanner trick as long as they fit nice and snug is the same as the screw drive, but now I run a belt drive so no need to take the caps off any more.

Ashley
 
but now I run a belt drive so no need to take the caps off any more.
Click to expand...

Yes!

Another advantage to my beloved belt primary

no leak

clutch stays dry

same belt for 12 years now, has never needed adjustment so that cover plug stays put!

and now with CNW's hydraulic clutch actuation, no need to ever remove the clutch adjustment cover plug

a forgotten primary, a good thing!
 
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