Carb screw broke - 96 XP

[seadooer2022]

Rebuilding the carb, the screw holding the tab that holds the spring is stuck and got stripped even though I was using a JIS screwdriver. Used an screw extractor on it, I think it was a 5m, and the head just snapped. What are my options here

 

[etemplet]

Try a Dremel with a cut-off blade and make a slot for a conventional screw driver. The fact that it broke off isn't good. Must be corroded in there. Maybe drill it and install a Helicoil. Very tedious job. The make left handed drill bits. Nothing guaranteed.. Good Luck with it. I have some carbs that have been gutted. $10 plus shipping.

 

[mikidymac]

I haven't seen that one break. It should come out super easy.

 

[burtshaver2021]

Is the carb steel or aluminum? If it’s aluminum you can easily weld a small nut to that broken bolt, if it’s steel you still can buy have to be more careful as you can weld the bolt into the hole.

 

[mikidymac]

All the carbs are aluminum.

 

[burtshaver2021]

I thought so, but couldn’t remember for sure. That would make welding a nut to the broken bolt pretty easy, the weld won’t stick to the aluminum even if it puddle did happen to come in contact. The heat created by the welding will also help dissolve the bond between the steel bolt and aluminum body. You may have to put a few spot welds on the end of the bolt first to build it up some before welding the nut to it

 

[seadooer2022]

Try a Dremel with a cut-off blade and make a slot for a conventional screw driver. The fact that it broke off isn't good. Must be corroded in there. Maybe drill it and install a Helicoil. Very tedious job. The make left handed drill bits. Nothing guaranteed.. Good Luck with it. I have some carbs that have been gutted. $10 plus shipping.

Will keep you in mind next time, decided to give the drill out a go. Picked up a tap and die set on Amazon, drilled out the hole with a m4, which is one size higher, then tapped with a m4, cut a nylon m4 bolt to the property length, fits pretty good

 

[mikidymac]

Get a stainless screw. No reason to use the nylon.

 

[seadooer2022]

Jotting these down for my own future reference

Mag carb Failing pop off test, wouldn't build up pressure, I know tester is good cause PTO carb tested ok.
Put soapy water around carb body, pulse line connector seems to be leaking, put the thing in a bin of water with needle/seat facing up so they don't get flooded, then finally reveals it was between these two pieces.


Note: no need to block off the pulse line, air doesn't go there.
In the mist of things, I must have put in the old gasket, found the new one, all is good now.

 

[seadooer2022]

Just wondering, can the carbs from 95 XP be used in a 96? Losing a bit of hp is ok.

 

[mikidymac]

No they are smaller.

 

[seadooer2022]

My Pop off now: mag=30, pto=35.
Is that okay? Already tried swapping the springs, no difference. They're the old springs, not the ones from the rebuild kit.
Genuine mikuni kits and valves/needles

 

[mikidymac]

Close enough. Don’t use the springs from the kit.