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Removing timing cover on 1981 xs400 Spc. II w/ electronic ign

Discussion in 'The Garage' started by brendonna69, Dec 5, 2017.

  1. brendonna69

    brendonna69 XS400 New Member


    This is my first post here. I reside in the small town of Athens, Ohio. I purchased my xs a few months ago from a friend in the military for a measly $150! It is a 1981 XS400 Special II, and has not been rode in 8-9 solid years. I just ordered a new cleaned up jug (seized pistons), have my plugs and carb rebuild kit. I also bought a battery and maintainer not too long ago along with some fuses. Upon further examination, I discovered that my bike has electronic ignition. As I examined the cover, I noticed someone had tried to drill out the right screw. The cap is missing and the screw head is half drilled away. The bit seemed to have traveled north and made a small cone shaped indent above the screw shaft. Is there any tool I can use to exract this screw? I will provide pix when I get home from work. It doesn't appear to me like the bit had pierced through the cover. Is it possible to replace the whole unit if it is damaged? What are some methods for removing this without damaging the head? Thanks
  2. not yet known

    not yet known XS400 Member

    I just drilled out some screws on a sprocket cover.. I tried impacting it out.. Tried slotting it for a straight bit.. In the end I just drilled it.. Started with a bigger bit.. Then cut out the rest with a small one..
  3. xschris

    xschris miles of smiles =)

    Post some pics. The electronic ignition pickup that is under the small cover off the cam had brass plugs covering the screws. If you plugs are gone then someone has drilled them out. The the screws are bad you will have to carefully drill the heads off to get the cover off. Once the cover is off the screws should spin out. Try not the damage the head where the screws go in it's aluminum. If you do, you may be able to drill and tap the next size screw to put the cover back on.
    Last edited: Dec 6, 2017

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