pilot screw assembly

[snarl]

I cleaned the carbs (1986 gs 550l) again but took out 3 of the 4 pilot screws (one is stuck). I need to know what order the rubber gasket, flat washer and spring go in for assembly as this stuff didn't come out on disassembly. I've got the bike running on three of the four cylinders and am going to clean carbs again.

[Nessism]

Put the spring on the needle, then the washer and the small O-ring last.

Did you soak the carb bodies in dip solution? Pull the pilot jets out and hold up to a light to make sure they are open?

Hope you get it right this time. Short cuts are long cuts when it comes to carbs.

[snarl]

Thank you. I've soaked them twice before and that got cylinders 3 and 4 working. This time I soaked them in simple green and kept it warm on a friends gas grill. So now cylinders 2,3 and 4 work. The pilot holes are all open. The only one I can't check is number 1 because that pilot screw is buggered up and stuck. I'll pull them off and clean again. Any suggestions on how to get the stuck pilot screw out?

[mike-s]

If the needle's screw head is truly shot and trying as large a screw as possible that just barely fits in doesn't work. Then i suggest you use easy-outs as an absolute last option.

First use a very small drill bit down the centre of the pilot screw (1-1.5mm diameter, 2mm absolute max, drilled about 5-6mm at most, just remember you need to safely be able to clear the thread of the carb body to avoid destroying it, so give a minimum of 1mm clearance from the inside edge of the thread and keep the carb in a vice to ensure you don't stuff the alignment that your drilling).

The use the easyout to remove it. If you have an option of the "screw in" vs the "hammer in" ones, go for the latter as they get a better grip on the object you need to remove, and most importantly don't forget to be GENTLE when hammering these things in so the aluminium body doesn't bend/crack.

[Nessism]

Heat and PB Blaster will work significantly better than Simple Green.

Many people cut off the snout of the carb where the screw is recessed and then use a dremmel tool with thin cutoff wheel to cut a slot in the screw head. Heat on the screw and work it both says until you get it to budge. After that use more PB Blaster, more heat, and work the screw back and forth. Once it moves, it's just a matter of time...just don't be in a hurry.

[snarl]

Well the screw is stuck because the threads are wrecked. Could I drill out the pilot screw and re-tap the hole? Or use a helicoil? Anyone know the thread count on the pilot screw?

[Johnny K]

Before you try anything else, spray some wd-40 and let it soak for a couple of minutes. Then after try to get the screw as dry as possible. Make sure the carb is secure and then put the screwdriver in the middle of your chest and bare down on the screwdriver almost your body weight on it as you try to unscrew the pilot screw. More force downward, then try to unscrew. Sometimes this works for really stuck screws and then if it doesn't, try the drilling part.

[ktp1598]

Maybe someoe on here has a spare carb? A while back, I had 3 or 4 of them lying around.

[snarl]

Success!!! I drilled out the bad threads. Drilled out the center of the screw and used an easy out. So I drilled the center of the pilot air screw out , tapped it, inserted a new screw with some thread locker and now have a functional pilot air screw. Thanks to everybody for the suggestions.