Trouble removing the VX800 Generator Plug without damaging it?  

from the VX800 FAQ, section 5.2 http://www.vx800.net/faq

Don't use a screwdriver to get the big generator cover plug out, since
the metal is soft and you'll probably chew it up. (that's the thing on
the left side of the engine with the giant slot in it, which you need
to remove to turn the engine over.) Use something that fits the slot
pretty closely. I was able to use a piece of thick sheet aluminum
filed to a curve to match the curved bottom of the slot. Rick Blunden
says it can be replaced with the plug from a Suzuki DR650 that has a
hex plug fitting.


In October 2000, I asked the order taker at Competition Accessories for the plug from the DR650.  Of course I couldn't tell him what year bike, so he just winged it.  What I got was Suzuki part#09259-36016-20H (what it said on the invoice), which supposedly comes from the '92-'95 DR650S.  It's cost me about US$8.00.  It would be wise to double check the part#'s just in case that was some sort of internal part number at Competition Accessories.  It also made me wonder if the plug changed substantially after '95 (somehow I doubt it).

It was an exact fit and color match.  The nice part is that by using a 10mm allen key, you can remove and replace it without any damage due to improper fitting tools.  Plus it looks pretty cool.  You might want to add a 10mm allen key to your toolkit, just in case you need to remove or tighten it on the road.

You'll need to re-use the o-ring from your current timing plug (part# 09280-33004), or purchase a new one.  This of course assumes you can get your current plug out.  

 

MotionPro sells a universal "timing plug wrench" tool (http://www.motionpro.com/servicetools_3.html  )



I've also heard you can get what's known as a "drag link socket".  It looks like a big screwdriver, and fits on the end of ratchet wrench.  I'm not really sure what it's originally designed for (drag links, I guess)
http://www.sears.com/data/product_images/tools/standard/00934299000-dv.jpg  They cost about US$6.50 for individual sockets, or US$19 for a set. 


Hugo in Denmark has created a very nice tool out of an old socket.  He says "I have cut a slice in a top and put in a piece of 3 mm tool steel. Round the tool steel edges and weld the steel to the top. The edges of the top will secure that the tool do not tilt." 
homemadetimingplugtool (1).jpg (166458 bytes)homemadetimingplugtool (2).JPG (170991 bytes)homemadetimingplugtool (3).JPG (85033 bytes)
(from http://hjem.wanadoo.dk/~wan21886/HugoE.htm)

I'm sure you'll be able to rig something up to do the job. Just make sure whatever you use fits nicely in the slot and does not bend easily. 

 

Click Here for info on damaging the plug due to incorrect procedures!

Click Here for info on damaging the plug due to incorrect procedures!