How to disassemble carb bodies??

[pnedac]

Hi GSers,

I appreciate the support. So here is the problem: I am building this GS for my neighbor and he requested 4-to-1 exhaust and pods so I needed to do a stage 3 kit to make that happen. I took the bike and kit to a buddy who is a drag races (cars and bikes) guy who owns a shop to make sure I don't screw anything up. We rejetted the carbs no problem, we vacuum synched the carbs and lastly, when we went to take the access plugs out (no problem there either) we found that the mixture screws were FROZEN solid. We put some blaster in there and let them sit overnight. Not one mm.

By this time we are concerned that we will be doing more harm than good as the pathetic screw heads are close to being stripped. That is when we resorted to the left hand drill bit. We made a pilot hole and then tried with the left hand bit and no matter how much it wanted to bite it just didn't.

New challenge: I just recieved today a new (used) set form another member (THANK YOU EL CORNUS!!!!). Get this. There was one single mixture screw that did come out easily on the sad set and on the new one that I got they all came out except for the one that did come out on the first set. So now I am going to have to marry the sets to get one good one. The lucky part is that it is the same carb body that needs to be switched. The #4 carb body.

I now need to figure out how to swap the bodies. Any advice there? The manual doesn't cover that, but I am sure I can do my usual digging.

Sorry for being so wordy. I am just trying to be thorough in my explanation. Did I go about this all wrong?

[chuck hahn]

Check you PM inbox and call me...way easier and faster to just tell you over the phone...

[chuck hahn]

You dont need to swap the bodies...you just need the screw out.

Do this..
Use a torch and heat the body by the screw hole. The rubber is seized against the carb body and hard as a brick and wont let the screw turn. Heat will soften that old rubber up so it can trun.

Once heated pretty good THEN a shot of penetrating oil to get it in and past the oring.

Now it should begin to move. Go out and in a little with more oil and slowly but steadily keep backing it out.

Next, reheat the carb body once the screw is out and wipe the hole clean with Qtips. look down there with a flashlight to see the hole is clean of any olg rubber debris.

Always lube the orings before you insert the scrws with some grease or vaseline to prevent them from resticking in the future.

Buggered up screw slots can be recut with a thin Dremel wheel if not too badly torn up.

[chuck hahn]

EDIT NOTE..it doesnt need that hard blowing flame that spreads all over. Meter it down to a small flame and heat just the tower the screw is in. Since its number 4, the screw should be easily accessable.

[pnedac]

Hey Chuck I appreciate the response and detailed instructions. I will surely give it a go when I get back to the workbench! You are the man!

[chuck hahn]

That rubber is ancient and stuck like someone super glued it in..the heat will soften..if not outright melt it. Just be carefull not to get the threads in the carb bodie itself goobered up...then youll be in for a swap situation.