im just glad this is a project bike. but now i just backed up the finish date by maybe a month or two :/ that sucks but atleast I MIGHT get it off... I'm waiting for my comprosser to fill up. I took a 1/2 inch metal chisel and cut a 1/2 inch square in it now im taking my impact wrench to it. God this is not the way to do anything if you dont plan on taking your full motor apart! Metal shavings in the crank case isnt what you want to ride with so dont try this unless you plan on a bottom end rebuild. :P but i hope this works it looks like it will ill let you know in a few.


WELL THAT DIDNT WORK EITHER. MY IMPACT JUST ROUNDED THE SOFT ALUMINUM OR WHATEVER THAT CAP IS. SO NOW IM JUST LIKE F IT GUESS ILL TAKE IT TO THE DEALER AND LET THEM WORK ON IT. DIDNT WANNA SPEND THE MONEY BUT I HAVE TO NOW. :/ IM DISAPPOINTED IN MYSELF. THE IDIOTS THAT OWNED IT BEFORE ME PROBABLY PUT LOCKTITE ON THE THREADS BC I SWEAR EVERY OTHER BOLT IVE TAKEN OFF THE BIKE HAS IT UP AND DOWN THE WHOLE BOLT. ITS BEEN A PAIN! WELL GOOD NIGHT FOR NOW ALL...

I just found a way to do it! ima drill to holes opposite of each other large enought for some screwdrivers to fit in and then take a pry bar and angle it between them and give it a spin. that sounds very promising. does anyone have pictures of the hole with the cover off so i can see how far i can drill the holes out. Thanks

 

Before drilling large holes, use a 1/8" bit, and sheet metal screws in the holes.

 

alright ill give it a try. i just picked out the drill bit for the screw drivers ha. but ill give the screws a try. ive bent a chisel trying to get this off so im not so sure about the screws...

 

okay...since a "rotor" is generally a reference to a brake part, I finally figured out that you are talking about the crankshaft hole plug.

I bet you're right about some genius coated it with threadlocker, they shouldn't ever be that hard to remove since it is an inspection hole

 

have you tried heating it?

 

If the cover is still on the bike you may be able to remove cover and work from the inside also you wont get shavings in your motor good luck

 

Heat can be a life saver for crap like that

 

alright heres the scoop... :P

I gave up after many words that would be censored here... and took it to the dealer and said have at it...

...Well... it's a small local Suzuki dealer so I was able to go back in the shop and watch/help with the removal. We started off with it in the vise, me and another guy holding the cover while the other guy had a 20 inch breaker bar... Didnt BUDGE! So we brought out the torch and gave it some heat for about a minute. Tried again with the breaker bar and we cracked the plug on one side. So at that point we decided to give it up and they had an extra cover laying around that I bought off of them for a good deal. So I have a cover that has practically NO scratches on it. Ill be honest I see one that is light and about 2 inches probably less near the plug in the middle from the previous owner that I can sell for a good deal if you wanna give the plug a go... :P PM me I'm open to offers! Take Care. Just glad the problem is resolved. took some money but no more headaches