Crankshaft screw cover

Anybody have trouble removing the screwed cap over the crankshaft bolt to be able to rotate the engine for the timing marks? 10 mm female hex. I can only assume it has been Loctited in. The hex is getting deformed and it won't unscrew. It has never been off before. To get to the timing marks, I took out the plugs, put it up on the center stand, put it 5th gear and rotated the rear wheel to turn the engine. But I still want it fixed. I'm thinking of buying a 11mm male socket and grind it to a taper so I can drive into the female hex and get a really tight fit. Then I'd replace the cap. Thoughts?

Mine got stuck after another shop put it in too tight. I ended up grinding a slot with a die grinder and using a 3" washer as a screw driver bit to remove it. I replaced it with a new one for better cosmetics. The 10mm hex wrench wouldn't move it even after using lots of penetrating oil and hammer blows.

Oh, I still have the old one if you want it.

Jim's solution is as good as any in getting the damned thing off. It is prudent to then use an anti-sieze compound on the threads of the new part when reassembling and of course, don't overtighten. Anti-sieze is also recommended on the final drive inspection cap and other similar caps.

Mike

It must be a fairly common problem. The plug on mine tried to round out when I removed mine, and I barely got it out. I gently put it back with some anti-sieze and ordered a new one from ebay and later replaced it. I don't think mine had ever been removed since the factory, as I was doing the first valve adjustment at 8K miles.

[...and of course, don't overtighten. Anti-sieze is also recommended on the final drive inspection cap and other similar caps...Mike]

+1 on that!

I had the same problem and started this thread:
http://www.nt-owners.org/forums/showthread.php?7113-How-to-Remove-a-Damaged-Crankshaft-Plug&highlight=

Thanks for the replies. I bought a 7/16 Allen Key, (Chinese), cut about 1.5 in off it with a good hacksaw blade - it was not that hard, then filed one end until I was able to drive it in full depth into the hex of the plug. Perfect tight fit. I then got a 7/16 socket on the other end and I guess I had about 80 ft lbs on it, and was tapping it at the same time. It just chewed up the female hex in the fitting and still didn't move. I tried 3 times getting fresh bites but nothing. The filed male hex was still perfect - that cap is so soft. So it was the $1 chisel from the local pawn shop, driven by tapping with a hammer near the outside that eventually got it broken out. This time the soft metal was an advantage as the chisel got a bite easily. Funny thing is it moved the tiniest amount then was free. I wondered if the swelling of the O ring may have been the cause. $12 for a new cover called for. Well and truly mangled now. But at least I did not have to take the entire cover off which was plan C.