Help needed! Dealer stripped Alan/Hex 30 mm crankshaft inspection cap

[zevk]

I was in the process of valve checks for my 2006 ABS ST1300 tonight....
I noted the dealer that serviced the bike last from previous owner (yes, name and shame! Ferntree Gully, Vic. Jeffrey Honda, no longer in buisness.... ) has worn of the soft walls of the 10 mm Alan / Hex inspection / crank cap on the front engine crankcase cover. 

http://www.bluecitymotorcycles.com.au/honda_search.php

parts
90087-kt7-000
90084-ky2-000

I also note he has mangled the o-ring of the cap which is visibly pinched and making a nice little mess....

The top (valve T1 T2) inspection cap was also mangled by the same heavy handed idiot, but I got it off eventually.

I have removed the front wheel and guard for better access.
 
I have tried the following to no avail:

slightly lager hex 11 + 12 mm, the end of a 1/4 inch socket extension and Torx driver

it's locked on tight and the 0-ring is likely binding the alloy cap to the cover.

I cant weld, tig, mig due to risk of creating further engine problems without removing case cover, I really dont want to remove the cranckase cover, oil etc...

I know a large grabbit / ezy-out will do the job, but involves drilling and thus, removal of the cranckase cover to avoid metal shards dropping into the sump...

I will try to use a hammer / persuader tomorrow to "set" a 1/4 inch extension bar, and hope to break the seal that has been created.... but would appreciate any advice from our fitter/ turner lathesmith professionals, if possible. I will order the damaged caps and o-rings tomorrow...

thanks
 

[zevk]

sorry guys, the search diagram requires input of 2006, ST1300, and assembly is "E-05 front crankcase cover"

thanks again

[Brock]

do you have a heat gun, an Impact driver and a hammer.

If you can, try heating the area around and away from the cap ( might loosen due expansion). load up the impact driver in the undo direction, and give a whack or two. should loosen enough to undo hopefully.

[zevk]

i have a heat gun and impact driver, will give it a shot tomorrow, thanks brock

[Brock]

Good luck

 

[zevk]

Happiness is getting a stuck bolt out!!!!!

I used a heat gun, 1/4 imch extension tapped hammered into rounded shoulders of 10 mm cap and a few knox and its out!!!!

[Shiney]

That's awesome news, glad to hear that all worked out

[zevk]

Photo of the offending parts...

I have a hate for large type “authorized dealerships” (dealer-shits) where techs (not mechanics) take little pride or ownership in their work, using old tools, wrong procedures and make a mess of things! 

I hammered a 1/4 inch extension into the rounded recessed hex cap inspection bolt, heated the area up with a heat gun, gave a few solid whacks and silent prayer, then it cracked loose. Big relief!

I will complete the valve clearance inspection and replace plugs with NGK Iridium type tomorrow. 
 
Hope I don’t need to replace any shims as it is a fiddly job, removing cams. 
 
I have ordered 2 replacement caps and O-rings so hope to get humpty dumpty back together again. 

[Brock]

See,

Us real techos know how to force things proper....