SuzukiSavage.com - Print Page

SuzukiSavage.com
/cgi-bin/YaBB.pl
General Category >> Rubber Side Down! >> Diaphragm / Needle Screw Removal
/cgi-bin/YaBB.pl?num=1474318100

Message started by notarealbiker on 09/19/16 at 13:48:20

Title: Diaphragm / Needle Screw Removal
Post by notarealbiker on 09/19/16 at 13:48:20

Hi all,

I'm new to this forum, motorcycling (been riding since June), and the Savage/Boulevard S40 in general (purchased a used 2007 back in July). So far I have fumbled through the petcock replacement (after an hilarious/embarrassing first ride with the wife mishap) and a muffler swap with relatively few hiccups. The muffler swap (Harley Wide-Glide slash cut) has been within the last week and much to my surprise I have not had any new issues with the carburetor that would lead me to believe a re-jet is necessary.

The bike has tended to stumble a bit mid-throttle in the lower gears ever since I bought it, even with the stock muffler installed. This leads me to believe that I need to do the white spacer mod. After figuring out how to remove the carb and remove the problematic cover screws (replacing with socket-head screws of course) I failed to get the needle cover screws out of the diaphragm - I was on the verge of stripping them. Does anyone have a clue as to the screw size / a reasonable method to remove them without drilling them out with a reverse bit? Thanks.

Title: Re: Diaphragm / Needle Screw Removal
Post by justin_o_guy2 on 09/19/16 at 13:57:42

Those screws, as much as they Look like Phillips heads, aren't.
They are JIS, but, you can grind the tip off of a Phillips and get it to drop into the X of the screw. Or, buy the right tools.
I've done both.

Title: Re: Diaphragm / Needle Screw Removal
Post by verslagen1 on 09/19/16 at 14:13:46

Harbor freight sells a impact driver about the size of a fat pencil.

Place the slide on a smooth surface when you're using it.

From the factory, all screws have some sort of locktite on them.

Sometimes all you need is a JIS driver and a lotta luck.

Title: Re: Diaphragm / Needle Screw Removal
Post by stewmills on 09/19/16 at 14:46:48

+1 on the JIS screwdrivers. Maybe try grinding off a Phillips as mentioned or an impact driver...just don't hit it so hard you break the slide.

I didn't have JIS and stripped one of mine. Had to get help drilling it out safely so I didn't tear things up.

Also, take the one that you did get out and see if your local ACE or nut/bolt shop has allen head replacements. You'll never have to worry with stripped screws again.

Title: Re: Diaphragm / Needle Screw Removal
Post by notarealbiker on 09/19/16 at 17:10:06

Thanks all. Would this be the impact driver you mentioned above or are you talking a small pneumatic ratchet?

http://www.harborfreight.com/impact-screwdriver-set-with-case-37530.html

Title: Re: Diaphragm / Needle Screw Removal
Post by justin_o_guy2 on 09/19/16 at 17:24:50

You're on the right track. Manual, hammer smack, but the old 1/4" , chrome one came with a long, skinny, Just Right tip for those
Down in There
Screws.

Title: Re: Diaphragm / Needle Screw Removal
Post by Kris01 on 09/19/16 at 18:08:46

http://suzukisavage.com/yabb2.2/Attachments/Carb_Screws_Web_001.jpg

Title: Re: Diaphragm / Needle Screw Removal
Post by verslagen1 on 09/19/16 at 18:52:18

6D696E6F7E7F787B717F681A0 wrote:

Thanks all. Would this be the impact driver you mentioned above or are you talking a small pneumatic ratchet?

http://www.harborfreight.com/impact-screwdriver-set-with-case-37530.html

that one is huge, you need a smaller one.

Wasn't able to find it, it's about the size of one of those multicolor pens.

http://www.harborfreight.com/media/catalog/product/cache/1/image/9df78eab33525d08d6e5fb8d27136e95/i/m/image_13794.jpg

Title: Re: Diaphragm / Needle Screw Removal
Post by verslagen1 on 09/19/16 at 19:08:41

dang... pretty hard to find. goto harbor freight, probably hanging there waiting for you.

http://www.ebay.com/itm/Central-Forge-7-Piece-Impact-Driver-Set-1-4-Hex-Head-93481-/122095236437?hash=item1c6d717555:g:agEAAOSwdzVXuf8H&item=122095236437&vxp=mtr

Title: Re: Diaphragm / Needle Screw Removal
Post by justin_o_guy2 on 09/19/16 at 19:50:41

That's the one to get.
I hadda take mine apart and slick up the ramps. But that's easy.

Title: Re: Diaphragm / Needle Screw Removal
Post by Kenny G on 09/19/16 at 20:35:45

I adapted a 60 year old KD Manufacturing Impact Driver to work on the carburetor on my S40. The KD has a 3/8" square drive and I purchased 3/8" to 1/4" adapter. I then use a quarter inch extension with the appropriate socket for a long Phillips Head Bit that I ground the head to fit those tiny screws.

I hold the carburetor in a Black & Decker WorkMate to work on it.

If you have a skinny enough soldering iron reach down in there and heat the screws long enough to break the sealer and then one light whack with a hammer on the Impact Driver and the screws pop right out.

I replaced the screws with true Phillips Head Metric plated steel screws from ACE Hardware 3mm x 6.

Impact Driver Pic attached.

Kenny G

Title: Re: Diaphragm / Needle Screw Removal
Post by Armen on 09/20/16 at 02:01:55

I like the Vessel Impacta drivers. Available in #2 and #3.
Whack them to losen, then use like a normal screwdriver.

http://www.ebay.com/itm/Vessel-Megadora-980-Impacta-P2x100-2-Cross-Point-Impact-Screwdriver-/152240659370?hash=item2372401baa:g:GdUAAOSwzaJX2FaR

-Armen

Title: Re: Diaphragm / Needle Screw Removal
Post by Kenny G on 09/20/16 at 06:33:50

Armen,

I have one of the Vessel Impact Drivers and the point on the screw driver tip is longer than a JIS screwdriver.

I did grind the Vessel down, but I still use my KD Manufacturing Impact Driver more often than not.

I am just saying.

Kenny G

Title: Re: Diaphragm / Needle Screw Removal
Post by Gary_in_NJ on 09/20/16 at 09:01:23

I'm a firm believer of "the right tool for the right job" rule, but I don't own a JIS screwdriver. As an alternative tool I have a 15" long screwdriver that has a shaft that isn't rigid - it allows some twist of the shaft. This allows a bit of wind-up and acts as a torque multiplier. With generous down force I've yet to find a screw that it couldn't loosen.

Title: Re: Diaphragm / Needle Screw Removal
Post by notarealbiker on 09/20/16 at 09:46:03

Thanks for all the tips - Harbor Freight is across town and kind of a pain in the ass to get to.... I may look into one of the skinnier alternatives available online. I'm in the midwest and trying to take advantage of all the (few) remaining nice days left this season. Will have to wait until the weekend to disassemble the carb again....

Title: Re: Diaphragm / Needle Screw Removal
Post by Kenny G on 09/20/16 at 12:32:44

I don't think you will find the smaller 1/4" drive Impact Driver at Harbor freight. The small Impact Driver has been discontinued for some time.

Kenny G

Title: Re: Diaphragm / Needle Screw Removal
Post by notarealbiker on 09/27/16 at 09:27:47

FYI, attempted to remove the screws again last weekend - this time with the impact driver. Another epic fail. Guess I will have to wait until I take the bike down for the winter and then drill out the screws....

Title: Re: Diaphragm / Needle Screw Removal
Post by verslagen1 on 09/27/16 at 09:41:25

You can grip the head of the screw with a pair of vice grips and twist'm out that way.

But they're not going to be pretty afterwards, get your replacement screws ready.