First time carb teardown

[exzachtly1]

In Ed's tutorial, it even tells you how the file down the screwdrivers for a perfect fit.
Follow his directions and use a lot of down force on what you are trying to unscrew with plenty of penetrant and you should be good.

Eric

Yeah, I saw that he had what looked like a fatter, filed down screwdriver. The problem is that wouldn't even help me... the 3 remaining pilot jets are already BADLY stripped from the PO. In fact, they're so bad that one of them appears to not have anything left to bite into. I am fearing that I will have to use desperate measures to get these out, like a screw extractor kit (destroying them) and replace with new.

The pilot screws are a little less worrisome but still giving me trouble.

EDIT: here are pics of the 3 stripped jets:

The last one was the worst one, and the only one i attempted to loosen. As you can see, now there is NOTHING left on it. It's completely flat.

Here are the 2 remaining pilot screws. First is near completely stripped. This one was definitely my fault, I got over-confident... but I'm hoping i can still work with it:

 

[Guest]

Ask Around

Ask Around

Someone may have the jets you need many guys fool with carbs around here. Hate to waste money on kits. If you have to replace them.

 

[exzachtly1]

In Ed's tutorial, it even tells you how the file down the screwdrivers for a perfect fit.
Follow his directions and use a lot of down force on what you are trying to unscrew with plenty of penetrant and you should be good.

Eric

Actually, I don't see an explanation of how to do the filing... what is the appropriate tool to use to file down a screwdriver that way? I'm assuming that you generally cannot find screwdrivers already made at that width that will fit inside the channels that these screws are in? Would you use a manual file like this to do it?

I have a screwdriver that is very close to working for the mixture screws, but nothing close for the pilot jets.

 

[GateKeeper]

that file can be used, or use can ue a bench grinder, or a dremel, or anything that will file the sides of the screwdriver down enough to fit into the hole and turn without hitting the sides....

the other important part is to get a screwdriver that fits the slot of the screw/jet properly and fully, as this will prevent from damaging the walls of the screw/jet and allow for easier removal

.

 

[exzachtly1]

Cool. I'm hitting a bit of a wall because I don't have some of these essential tools... no heat gun, no vice grips to hold the carb body for me while I work, no dremel / files, no extra screwdrivers to file down (I have a couple of normal screwdrivers, but none the appropriate size. All of the others are bits that go into a ratcheting driver, which have been perfect up until now).

Starting to feel the pain of how much money I'm probably gonna have to spend to do this right. I'm definitely going to have to buy new float bowl gaskets, pilot jets, and maybe even a couple of fuel mixture screws. I'm worried that one of them is too stripped to continue using after I get it out.

Everything was coming apart so easily up to these few final screws... such a bummer

 

[exzachtly1]

Well I've just ordered new pilot jets, plugs, and float bowl gaskets (the old ones were pretty shot, one fell apart). Bikebandit had a pack of 4 pilot jets for $12 (Mikuni 42.5).

So... at least I will have everything ready when (if) I can get the stripped jets out.

In the meantime I will continue to accept any advice for dealing with these things. I think one of the screwdrivers I have is the perfect size for the mixture screws, but wont fit into the channel. I put together a shopping list...

bench vice clamp (to hold the carb body)
left hand drill bit (please advise if this is the best method for the stripped jets)
screwdrivers - .0385" for mixture screw, .0350" for jets (or just use existing screwdriver)
file
torch

 

[exzachtly1]

Question - assuming I have trouble with the mixture screws and (worst case) I need to replace one or two of them, where can I find a replacement? I haven't been able to spot them anywhere online. Closest thing was on Z1:

http://www.z1enterprises.com/ItemDe...(BS+Series)+GS750+GS850+GS1000&item=KL18-2645

But that says it's for the BS34. I'm confused though - Ed's tutorial says that GS550, 650, 750, and 850 share the BS32? Will this part fit my GS650? It sure looks like it will and I just want to be prepared in case I have to replace any of these.

 

[exzachtly1]

I did some searching on the forums and I think I might end up trying Steve's suggestion of re-slotting the mixture screws with a hack saw or dremel. I am probably going to have to ez out or left-hand drill the pilot jets.

Do you guys think that soaking the carbs in the carb dip before doing this stuff will help loosen the threads on these remaining screws? I understand that it will probably eat the rubber gasket on the mixture screw - will that be a problem? I have the replacements from cycleorings.com already.

Picked up a propane torch for heating, some new screwdrivers that should fit much better, and an ez out bit today. I may be posting in the "parts wanted" section soon if things don't go my way

 

[GateKeeper]

Always think positive.....

 

[exzachtly1]

VICTORY!
...almost

I got the 3 pilot jets out. Here's what worked for me - read this a couple of times and decided to give it a whirl since I remembered that I actually did have a Torx lying around...

T8 torx, set it in the center of the jet head with a few firm whacks with a rubber mallet. This gave a really good bite and i was able to press down with all my strength on the bench and turn the carb body with my other hand. POP! Came right out. No heat required.

Now I still have to deal with the 2 damaged mixture screws. I plan to tackle that later with the slot method, copious amounts of heat and PB blaster. My only concern - will the heat melt the rubber o-ring inside? I have replacements BUT i dont want to gunk things up in there with melted rubber.

 

[GateKeeper]

Good on you for getting those out.....The sweet taste of Victory,,,,is great...

don't worry about the rubber, if your dipping the carbs all of that should get cleaned out anyways, spray some air in the passage, carb cleaner, etc....to make sure it's all gone...

slow but sure and you will have success....

.

 

[exzachtly1]

Good on you for getting those out.....The sweet taste of Victory,,,,is great...

don't worry about the rubber, if your dipping the carbs all of that should get cleaned out anyways, spray some air in the passage, carb cleaner, etc....to make sure it's all gone...

slow but sure and you will have success....

.

Thanks man. Definitely feels good. Now my only concern with the re-slotting strategy on the mixture screws this: won't cutting down into the channel with a dremel mess up the interior threads that the screw goes into? If so, what do you do about that?

 

[Steve]

Thanks man. Definitely feels good. Now my only concern with the re-slotting strategy on the mixture screws this: won't cutting down into the channel with a dremel mess up the interior threads that the screw goes into? If so, what do you do about that?

Can't tell you exactly how many times I have had to do that, but have never had a problem with the threads when I was done.

I use a Dremel with a large cut-off wheel to slot the tower, I think you might have seen the pictures before, I can re-post them if you want.
Your biggest challenge will be to cut down the center of the tower, so the new slot in the screw will also be in the center.

Or, if you have managed to convince your wife that I'm not some average creep from the internet, I can stop by on Saturday afternoon to give you a hand for a bit on my way home. It is getting close enough that I am trying to nail down my schedule, so this will be your last chance to grab a couple hours of my time. :-\\\

By the way, I have some mixture screws with me.

.

 

[exzachtly1]

Can't tell you exactly how many times I have had to do that, but have never had a problem with the threads when I was done.

I use a Dremel with a large cut-off wheel to slot the tower, I think you might have seen the pictures before, I can re-post them if you want.
Your biggest challenge will be to cut down the center of the tower, so the new slot in the screw will also be in the center.

Or, if you have managed to convince your wife that I'm not some average creep from the internet, I can stop by on Saturday afternoon to give you a hand for a bit on my way home. It is getting close enough that I am trying to nail down my schedule, so this will be your last chance to grab a couple hours of my time. :-\\\

By the way, I have some mixture screws with me.

.

Thanks Steve. A buddy and I are going to take a crack at them tonight, and I'll let you know what happens. Hate to have you work the trip into your schedule if we end up taking care of it without issue.

I don't have a dremel, but i have one of these. Hoping it will work with the rounded metal cutting attachment - I used it to slot one of the gang rail screws that was seized and it worked fine for that. Figure i can start the slot with a hack saw (i've done this on one post already, seems pretty centered) and go from there.

If we still can't get them loose I'd be glad to have you stop by. The tentative time would be around 4:00 probably, but I will let you know for sure before the end of the night. I may be interested in those mixture screws! Z1 said the ones I found on their site were not exactly the right size (he said they had a slightly different taper - dont know if that matters?) Seems weird that they sell the 650 screws in a kit but not individually.

Wish me luck

 

[exzachtly1]

YESSSS! I got them out, the heat + PB method worked GREAT. A couple of rounds and they backed right out. I wish I had done this in the first place, because now I have a couple of fairly stripped screws. They're not so stripped that I couldn't work with them but I either want to re-slot them or get new ones.

Steve - thank you so, so much for the offer but at this point I am going to be waiting for parts and reassembling things over the weekend, so there's not much reason for you to go out of your way to stop here. However, I may be interested in buying 2 mixture screws off of you; it's not an immediate need but I'd love to replace the stripped ones. Maybe we can work something out? Let me know!!

And finally, thank you guys so much for the support through this. I really appreciate not being judged for the newb mistakes I have been making

Should be uphill from here, the worst is over! First carb body is in the dip right now.

 

[Steve]

..., so there's not much reason for you to go out of your way to stop here. However, I may be interested in buying 2 mixture screws off of you; ...

I just checked the difference in the route. Of course, I don't know where in "Akron" you are, so I just plotted a route through downtown. It adds a whopping 11 miles to the trip.

I could just drop the screws off as I go through, but will probably be there a bit earlier than 4. Send me your address in a PM, and tell me where to leave the screws, I'll drop them off as I go by.

And finally, thank you guys so much for the support through this. I really appreciate not being judged for the newb mistakes I have been making

Oh, don't worry, you have been judged. We are just too civil and polite to rub your nose in it.

.

 

[exzachtly1]

Steve -
Sent you a PM. Let me know if you didn't get it, it isn't showing up in my "sent messages" folder for some reason. Weird.

As for being judged... I expected that

I'm a hands-on learner though, and very stubborn. I like to accomplish things like this by doing it myself and learning the hard way if I have to! Now I know some tricks and I won't make the same mistakes in the future. Someday hopefully I can give some advice to someone in my position

I'll revisit this thread if I have any issues with the rebuild. Thanks again.