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can not remove idle mixture screws

  • Thread starter Thread starter karllmt
  • Start date Start date
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karllmt

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I'm sure some where this has already been addressed - But here is my situation. GS750E 1980 all stock. I have dissembled the carbs a couple times before and cleaned, but have never done a compleate re build, because I can not remove all idle mixture screws. Caps are off. #1 comes out, no problem. #2 turns out about 4 turns and stops. #3 & 4 will not budge. Have soaked with PB Blaster and used heat gun. Still no dice. Any suggestions?
 
Does your screwdriver fit tight into the screw head? You need the blade to fit, and fill the full width of the screw. I took an old screwdriver and ground it down until it fit nice and snug into the slot.

To remove the screw I'd keep up with the heat cycles and the PB blaster. Try to work the screw both in and out. Once you get them to move it's just a matter of working back and forth, spraying, and heating. Take your time and don't force anything and usually you will get them out.
 
I actually bought a new "Craftsman" screwdriver to fit into the small hole. Blade seems to be fairly snug. I will continue with the PBB and heat. Is there anywhere I should be spraying besides the top?
 
Sorry you are having such a hard time with this. How much heat are you putting on the carb body? I'd get it good and hot but not crazy hot since the throttle shaft seals could get damaged. Fill up the tunnel the screw sits down in with pent. spray and heat the crap out of the carb. And again, work the screw both ways, in and out. Keep trying.
 
Yes, I am concerned about applying too much heat. Don't want to damage anything. My next step (tonight or tommorrow) is to skip ahead and dissamble everything from the bodys and try again, using more heat.
 
you may want to try dipping it while it's still in the carb but everything else has been removed. The ChemDip should break up any crap that's in there and when you rinse it off it should be easier to get it out.
 
Thanks for the suggestion. That thought had crossed my mind. Will try tommorrow.
 
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Here is your very own magical, mystical, mythical, mind-expanding "mega-welcome". Please take notice of the "Top 10 Common Issues", "Top 15 Tips For GS Happiness", the Carb Cleanup Series, and the Stator Papers. All of these tasks must be addressed in order to have a safe, reliable machine. Now let me roll out the welcome mat for you...

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Thank's for the welcome BassCliff!
I'll be back on the carb teardown Tuesday. Hear's hoping I can get the screws out.:pray:
 
We have a break through! At Tenrilid's suggestion I removed everything from the carb body (#4) except the stuck screw, and dipped it in carb cleaner for half an hour. After wiping it off and applying some heat, I used Nessism's suggestion of a better fitting screwdriver ground down on the sides so it fits down the hole. And it budged. After a half hour of PB blaster and heat and working it back and forth, it backs out about 5 turns. Close but no cigar! I put it back in the dip and it's soaking over night. I'll try again tomorrow.
 
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YAY! I'm glad to see you made some progress on it. Hopefully soaking it over night should allow it to break up any other crud that is in there to let you take it out. Good luck and keep us informed.
 
The overnight soak should do the trick, but have you inspected the threads above the screw? Might help to lightly run a pick in the grooves to clean any bits of poo that are impeding progress.
 
still stuck

still stuck

Here is the situation, as I see it. After soaking overnight, the screw on #4 backed out another turn or two. But that has taken 2 hours of working it back and forth. And remember I have 2 more to remove. Comparing #1, which came out first try, to the others. The threads on #1 come up about 1/4" of the top, #4, the one I'm wrenching on, I see no threads past where the screw is. Maybe the threads were damaged or reemed out by a PO. Even with my new tight fitting screwdriver, the slot is getting chewed by this point. I'm not sure where to go from here.
 
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I'm rebuilding a set of 1150 carbs at the moment and the tunnel isn't threaded all the way to the top. This makes sense since Suzuki pressed a cap into the tunnel to discourage messing with the mixture (for emissions reasons).

Not sure what to suggest other than keep trying. Hopefully you are getting a good feel for how much force can be applied before stripping the heads on the screws. At some point you may have to gamble and use a little extra force and hope for the best.

A fix for a damaged pilot screw slot is to cut into the tunnel with a dremmel cut off disc and cut a new slot in the screw. You have to chop off the top section of the tunnel first for obvious reasons. There is no harm in doing this other than cosmetics so consider that your back up plan.:)
 
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You might try turning the screw all the way in and chasing the top threads with a tap. I THINK it's M4 x .7 but wouldn't guarantee that.
 
old_chopper said:
You might try turning the screw all the way in and chasing the top threads with a tap. I THINK it's M4 x .7 but wouldn't guarantee that.
Click to expand...

It's M6 X 0.5. Might be worth a go though getting the ends of the thread to match up will not be possible.

I would wind the screws out as far as they go and measure. Then using a depth gauge drill slightly oversize down to that depth and then unscrew. You don't need threads all the way down to keep the things in.
 
mike-s said:
Ebay/new carbs would be my first suggestion.
Click to expand...

This was my first thought also. I may try drilling or threading suggestions as well. SPCHIPS has a set of carbs for sale (for parts) from a 81 650. http://s94.photobucket.com/albums/l115/spchips/GS650GL%20Parts/ Does any one know if the bodies of his are the same as mine (80 750) ? Last year I bought a bank of carbs for spare parts, but turned out to be not compatable. Mine seem to be exactly like the set in the carb cleaning series; which I am using for most of my instructions.
 
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to change carb bodies, or drill away?

to change carb bodies, or drill away?

karllmt said:
This was my first thought also. I may try drilling or threading suggestions as well. SPCHIPS has a set of carbs for sale (for parts) from a 81 650. http://s94.photobucket.com/albums/l115/spchips/GS650GL Parts/ Does any one know if the bodies of his are the same as mine (80 750) ? Last year I bought a bank of carbs for spare parts, but turned out to be not compatable. Mine seem to be exactly like the set in the carb cleaning series; which I am using for most of my instructions.
Click to expand...

I heard from spchips. He said the bodies from his '81 650 are the same as my '80 750. Can anyone else confirm this? I'm hoping to go look at them; he isn't too far a drive.
 
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