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Message started by MiamiBobbed on 03/24/22 at 14:37:45

Title: Air Fuel Mixture Screw-ed
Post by MiamiBobbed on 03/24/22 at 14:37:45

After purchasing a small slide hammer to drill and remove the brass plug covering the screw on my 2011 S40, I find that the screw was cranked all the way IN, the slot was already worn and it would only move 2 turns before it gave up completely. Now the head slot is completely worn and I would prefer to get the screw OUT somehow instead of buying a used carb. Any tips? What size is the screw? I think it's an M5. Any help would be greatly appreciated! THANKS

Title: Re: Air Fuel Mixture Screw-ed
Post by TheSneeze on 03/24/22 at 15:11:27

A very small drill, and a matching easy-out. Delicate and difficult work, I'm afraid.

Title: Re: Air Fuel Mixture Screw-ed
Post by Dave on 03/26/22 at 03:32:03

I am not home and cannot type a detailed response using my phone- I will provide some better help when I get home tonight.

Title: Re: Air Fuel Mixture Screw-ed
Post by justin_o_guy2 on 03/26/22 at 12:19:29

I'm predicting another
Gold Star
response.

Title: Re: Air Fuel Mixture Screw-ed
Post by Dave on 03/26/22 at 18:22:46

Here is the link to the Technical Section where a "TORX" bit can be used to remove the stripped screw.
http://suzukisavage.com/cgi-bin/YaBB.pl?num=1350749896/0

The threads in the carb body corrode and expand a bit - and after many years of corrosion it becomes hard to get the brass screw past the corroded threads without stripping the soft brass slot. Using a penetrating lube helps the thread issue - but also hinders the ability to keep the screw driver firmly in the slot. Once you get the old stripped screw out - it is entirely possible to strip a brand new one while putting it in past the corroded threads (spoken from first hand experience). I now own a tap to clean up the thread before I install a new screw.

I have pretty good luck getting the center of the screw drilled....I first start with a small pointy Dremel cutter to get a center point for the drill to start properly....then use the drill size as detailed in the link provided.

I am tempted to machine a plug that can go into the carb body where the brass plug was that blocked access - and have a center hole to act as a guide to center the drill....and maybe even a stop so you don't drill too deep.

Title: Re: Air Fuel Mixture Screw-ed
Post by MiamiBobbed on 03/30/22 at 14:29:55

Thanks for the tips!

Ultimately, I very carefully drilled the mixture screw "out" starting with a small to larger bit and staying just under size of the screw. I was actually able to unscrew the "shell" that remained and used a small dental pick to remove the peices of the needle tip, spring and o-ring. Not wanting to test the integrity of the hole threads on the new mixture screw, I went ahead and bought the M6X0.5 tap on Amazon and ran the threads with it. The new mixture screw went in like butter....for now.

As a side note, this bike had been sitting for a few years and every outer and inner screw on this carb was corroded/rusty/stripped/ruined. The entire process to get it rebuilt was a fight and this forum helped me every step of the way...I really appreciate the posts you guys have created for newbies like me!

Title: Re: Air Fuel Mixture Screw-ed
Post by justin_o_guy2 on 03/30/22 at 15:16:29

Your skills saved your butt! Good goin,,
And dropping a few bucks to get the threads right and not risk a problem was smaaart.

Title: Re: Air Fuel Mixture Screw-ed
Post by LANCER on 03/30/22 at 17:25:13

A stainless steel set of Allen head screws are available for $15; 4 for the top, 4 for the bowl cover, and 3 for the little side cover of the stock CV carb.
Holler if you want one.

Title: Re: Air Fuel Mixture Screw-ed
Post by MiamiBobbed on 03/30/22 at 17:32:21

Thanks Lancer. I went to ACE and bought stainless allen head screws based on this pic from verslagen1: http://suzukisavage.com/yabb2.2/Attachments/Carb_Screws_Web_001.jpg

They cost more than $15!!

Title: Re: Air Fuel Mixture Screw-ed
Post by LANCER on 03/31/22 at 03:42:58

I get screws from a local Fastenal store in packs of 100, it’s a better price/screw.