Air Screw Extraction Gone Wrong - A Cautionary Tale

[J_C]

My first day back from a two week vacation has proven to be frusterating at best. I started by stripping the head of one of the four philips holding on the diaphragm cover. Then, when attemping to remove the air screw, that got stripped too. Attempting to Drill it out, followed by an attempt with a screw extracter led to a broken #2 carb body... the force split the threads and the whole side of the air screw part broke off.

So far my carb casualties include:
Broken #2 carb body
Two stripped screws (1 diaphragm, 1 guard rail thing)
One annhilated air screw
Bad idle adjust knob (not caused by me, threads wore down)
More screws and gaskets to come I'm sure

Long story short, if you haven't broken a carb body, know that its extremely easy to do. If anyone has any tips on how to remove a seized air screw then please let me know.

[speedzter2000]

I had the same problem....
I brought it to a guy, and he used the extractor, BUT...heated up the carb body with a torch (just where the screw was) and the darn thing came right out. Meanwhile, this was AFTER I completely stripped it, and tried other ways to get it out. They guy who did it for me told me when he put the screw extractor in, he could feel it stripping the screw...so, that's why he heated it. I was VERY happy to say the least.
As far as getting to the diaphragm cover bolts , I used Vise Grips..I already knew I was going to have a problem. WD-40'd it, then the screws came right out..(this was AFTER stripping one of them)...
Good luck

[J_C]

Damn, can't believe I didn't think of heat... I wonder if they sell like cheap mini butane torches or something, I don't think my lighter is going to cut it :-D

As for the regular screws, haven't had a problem at all using a dremmel to turn the mangled phillips into a bigger flat head, but I wish I could stop stripping them in the first place

[chef1366]

CV carbs

You need an impact screwdriver. I do have a whole set of carbs for your bike. If you want to keep it stock, I have what you need.

[fifer]

Butane torches

They do sell mini butane torches and they are affordable and very handy.

[J_C]

Cool thanks fifer... any leads on where to buy?

Chef, thanks I actually sent you an email this morning; let me know. Cheers!

[Road_Clam]

My first day back from a two week vacation has proven to be frusterating at best. I started by stripping the head of one of the four philips holding on the diaphragm cover. Then, when attemping to remove the air screw, that got stripped too. Attempting to Drill it out, followed by an attempt with a screw extracter led to a broken #2 carb body... the force split the threads and the whole side of the air screw part broke off.

So far my carb casualties include:
Broken #2 carb body
Two stripped screws (1 diaphragm, 1 guard rail thing)
One annhilated air screw
Bad idle adjust knob (not caused by me, threads wore down)
More screws and gaskets to come I'm sure

Long story short, if you haven't broken a carb body, know that its extremely easy to do. If anyone has any tips on how to remove a seized air screw then please let me know.

Yup, we've all been there. Archive some posts I made about the EPA plug, and air screw removal gone horribly wrong. I ended up having to purchase a whole new rack of carbs. It doesn't end at the carbs. Many of us have major problems removing the exhaust bolts, and the valve cover bolts. I snapped a V/C bolt right under the coils, so I had to pull the whole engine assembly !!!!!!! (to add insult to injury, 3 months later I had to yank the cylinder head AGAIN to repair a bad head gasket!!!!!

[J_C]

Bummer! I just read your old posts. You don't happen to have a spare #2 carb body would you?

[GS550joe]

Mini torches

Check wal mart in the hardware section... about $28.. looked at one l;ast night... uses butane lighter fuel..

Joe

[lapls]

Sorry but..... I would hesitate before using an open flame near a carb.... ;-)

As for removing those 5mm bolts on CV cover and bowl, I use a good screwdriver and if needed I clamp vise-grips on the screwdriver shaft and apply pressure with my arm to keep the phillips in it's hole, then turns the vise-grip to unscrew.. Works 99% of the time, for the last 1% I use needlenose vise-grips that I clamp firmly around the head .. I am not found on using an impact on a carb, maybe I should try it..

Sylvain
GS650GL
XS650SG

[Road_Clam]

Sorry but..... I would hesitate before using an open flame near a carb.... ;-)

As for removing those 5mm bolts on CV cover and bowl, I use a good screwdriver and if needed I clamp vise-grips on the screwdriver shaft and apply pressure with my arm to keep the phillips in it's hole, then turns the vise-grip to unscrew.. Works 99% of the time, for the last 1% I use needlenose vise-grips that I clamp firmly around the head .. I am not found on using an impact on a carb, maybe I should try it..

Sylvain
GS650GL
XS650SG

There is absolutely NO replacement for a phillips impact driver!! They make loosening 25 year old skanky phillips screws a BREEZE!!!!

[Road_Clam]

Bummer! I just read your old posts. You don't happen to have a spare #2 carb body would you?

I have a set of bare carb bodies, I can't remember which carb has the stripped air screw threads. I will check them tonight.

[mixongw]

They do sell mini butane torches and they are affordable and very handy.

What's the melting point of zinc?

[DaveDanger]

that'd be 787 degrees fahrenheit.
I've had decent luck heating aluminum and zinc parts for fastener removal with a commercial heat gun. Resembles an industrial blow dryer. Home Depot, Lowes and such carry them for paint removal and other odd jobs. In the high position, they put out a lot of heat.... with NO flame.

[Jethro]

$12 at AutoZone: