damn valve covers!!!

[mikeman828]

Alright, I need some serious help here....

I bough a 2002 400ex last June, I was getting ready to adjust the valves this past weekend and when I got it apart, I couldn't get the damn covers off!!!! (I doubt the kid I bought it from ever did any work on them so they have never been off)
I tried soaking them with liquid wrench, but no luck!!! Because they are not true metal, they also started to round the corners of the hex head on the covers......

Help.... any suggstions to get them off would help!!!

(I will be getting new ones when I get them off)

Thanks!!!

:confused:

[UglyMotha™]

after you've rounded them to the point that a socket will no longer do any good, a pipe wrench will work great, and then you can replace the covers

[2004TRX450R]

First try a 6 pt. socket. If you are rounding the edges I'm asumeing you are useing a crecent wrench? If it is to messed up for a socket try a set of vice grips. If those don't work take a hammer and chissel and try hitting the outer edge of them in the direction that would loosen them. This usually works pretty well as a last ditch effort if you plan on replaceing them. They are true metal. They are just aluminum and the reason the penetrateing oil won't work is because they have a rubber O ring sealing them.

[Bob-Hobo]

This happened to me, i took it to a shop before i completely ruined them all, they used a 6 point socket and an impact wrench. I had both but didnt wanna try a big impact wrench on them myself.

[cals400ex]

Originally posted by Bob-Hobo
This happened to me, i took it to a shop before i completely ruined them all, they used a 6 point socket and an impact wrench. I had both but didnt wanna try a big impact wrench on them myself.


boy bob, or should i say toby, your a smart fella for only having 34 posts. :p


i agree, definately replace the covers when you get them off. don't overtighten them either. i think they only go on with 11 or 12 ft-lbs.

[BIGRED400]

My Clymer says 11 ft. pounds

[ewalker302]

a socket/ratchet will break the tool or the cover before it rounds anything off.........cheater bar.

I snapped a craftsman (1/2")!! extention, trying to take lug nuts off a backhoe.

:bandit:

[mikeman828]

anyone know what size 6pt socket they take???

I tried all the ones I have and they were all too small. I did use an adjustable as a last resort...


:(

[dhines]

They are 24mm if I recall correctly.

[300expower]

i never saw valve covers on a 400ex but if they are like the ones on my 300 you could use a dremel and cut a line to make it look like a flat head screw driver, and then you use a ratchet with a flat head in a socket to unscrew it, i'm not sur at 100% it will work :o