Remove Broken Pilot Fuel Screw Tip From VM Carb Body /w Pics

[jimcor]

Here's the email reply I got from motorcyclecarbs folks regarding purchasing new pilot fuels screws (this for 79 GS1000):

To get the pilot screw you will have to order the kits.

Try this link instead:
www.motorcyclecarbs.com/CARBURETOR_REPAIR_KIT_SUZUKI__P5188.cfm

[1100lt]

what if the screws were hit by a drill bit and took out the top. I can't adjust the screws do to po drilled the caps out and messed up the top of the screw. Any ideas. Thanks Dan

[Hoomgar]

what if the screws were hit by a drill bit and took out the top. I can't adjust the screws do to po drilled the caps out and messed up the top of the screw. Any ideas. Thanks Dan

Dan, if there is enough metal left try cutting a slot in it with a Dremel tool. If that is a no go you can try an easy out *cringe* but be very careful.

If the hole is centered well enough you can also step drill it out by going one size larger in steps until the plug is thin enough to crush and pull out. If you go the last route you have to be careful to not go any deeper than the threads. Look at another screw to see how far to set the stop on your drill bit. Electrical tape works great for the stop. If you go too deep you will be down into the hole where the taper end goes, thats bad.

If you can get it out of there without damaging the body you will be OK. I know I would have to problem trying it myself but I am always cautious about telling others to try things like this just because...

Those screws are very soft brass and you can get it out without damaging the carb body if you take your time with it. Hope it works out for you my friend.

[midnightcafe]

thank god I found this post! real lifesaver, can't wait to try it on the broken fuel screw

[midnightcafe]

I found the easiest way was to tape off the front of the carb body to avoid damage if the tool slid.

First I kneaded the brass tip by rolling a screwdriver over it to push it down the hole.


I couldn't get my hands on a punch or any fancy tipped tool, so I sharpened the tip of a metal knitting needle instead. Lined up the needle with the hole, tapped it three times with a hammer and it slid RIGHT out!

[gremlin]

what if the screws were hit by a drill bit and took out the top. I can't adjust the screws do to po drilled the caps out and messed up the top of the screw. Any ideas. Thanks Dan

reverse drill bit. drill slow when the big catches it will back the screw out. or a small drill bit and drill a line of holes. then remove the stuff in the middle to make a new slot.

[79FiveFifty]

thanks for making this post, I'm going to buy and awl tonight if i have time.. I dismantled all my carbs and broke 1 of the pilot fuel screws.. I hope i have good luck removing it.. I tried sewing needles and such, no luck it's really stuck in there good maybe the extra length of the awl will press it right out.

[79FiveFifty]

Ok, my awl isnt the correct angle, but i got it removed by manipulating a thumbtack.

the night is ok afterall.

[Nessism]

Bumping this back up. Great thread.

[Adler]

Bumping this back up. Great thread.

Awesome! Thanks for bumping this back up, definitely relevant to my interests, ill give it a shot.

[lucabond]

I used thumb tack with a screwdriver on top, put a Popsicle stick between the body and the screwdriver which gave me better leverage and kept the carb body from getting marked up. Good luck.

[tedwoodstrong]

I'm ordering a Suzuki Carb Repair Kit today along with a service manual. When they come in and I get my carb cleaning fluid, I'm going to try this. Thanks for inspiring confidence!

[Nessism]

I'm ordering a Suzuki Carb Repair Kit today along with a service manual. When they come in and I get my carb cleaning fluid, I'm going to try this. Thanks for inspiring confidence!

Dude, do some research before you order anything. Check the Newbie Mistakes thread linked in my signature and search out Basscliff's website for a free factory Suzuki service manual download.

[tedwoodstrong]

Thanks for that link. I should clarify that I'm ordering only the new rings and pilot screws. I'll definitely be trying to download the service PDF. While I'm at it, I don't see the harm in taking Bikecliff's advice and finding a new petcock, as the current one was constantly set to prime by the PO.

[tedwoodstrong]

Here's some additional methods that others have tried:

http://www.xs11.com/xs11-info/tech-tips/repairs/35/98-idling-problemsidle-mixture-screw-broken-tip-removal.html