Help! Inspection cover stuck

craigster266 · L Plate Warrior Joined: 31 Oct 2015 Karma :

I'm trying to remove the inspection cover on the crank case of my YBR125 so I can do the valve clearances, but the thing won't budge. It's made of plastic and, despite using a large wide screwdriver, the thing is just chewing up. I don't mind replacing it, but any ideas how I can remove this?

Burnzy1989 · Nitrous Nuisance Joined: 06 Apr 2009 Karma :

Pete. · Super Spammer Joined: 22 Aug 2006 Karma :

Drill two small holes in it opposite each other. Put a short self-tapping screw in each hole and use a screwdriver across the screws to undo.

Try not to screw the cover to the threads by putting the holes too near the edge.
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Suntan Sid · World Chat Champion Joined: 07 May 2009 Karma :

Find a socket of, roughly, the same diameter, cut out a piece of plate metal that fits inside and across the diameter of the socket and you'll have made the giant screwdriver you require!
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WD Forte · World Chat Champion Joined: 17 Jun 2010 Karma :

I've used large-ish washers that fitted the slot width snugly
then dressed them with a file so they bottomed nicely in the slot
then held them in the jaws of mole grips/shifting spanner/whatever is to hand and pressed them in whilst turning.
Screwdrivers will just chew the slots
Taking the time to make a suitable tool will be quicker and less of an arse ache in the long run.
I always give the threads and O ring a good dollop of copperslip before assembly which makes the job so much easier and quicker the next time.
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cb1rocket · World Chat Champion Joined: 30 Jan 2010 Karma :

Tyre levers are good, the ones with a flat edge
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Ed Case · World Chat Champion Joined: 01 Mar 2009 Karma :

Firstly order a new one, then a light hammer and a sharply pointed punch to the existing one. If it isn't knackered by now it soon will be.

craigster266 · L Plate Warrior Joined: 31 Oct 2015 Karma :

Raffles · World Chat Champion Joined: 14 Apr 2009 Karma :

Pissed-off with chewing-up inspection covers etc, I decided to purchase one of these:-

https://s22.postimg.org/a9ndiz6qp/IMG_5835_1.jpg

It only cost me around seven ponds and is much easier and betterer than fucking around with Heath Robinson solutions.
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Robby · Dirty Old Man Joined: 16 May 2002 Karma :

Hold a coin in a pair of grips. Tends to fit the slot well.