How to drill out the pilot screw cover - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
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post #1 of 8 (permalink) Old 10-2-2013, 7:48 AM Thread Starter
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How to drill out the pilot screw cover

Hi guys I'm sure you've seen similar topic before but I'm worried I might mess things up. I pulled out my carbs and cleaned it very well only thing is I could get to the pilot screws because they are covered with some sort of metal on top and I'm scared to drill them out. Do you guys have any recommendation or how to do it safely? Also what are the specs on tightening up the pilot screws etc...
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post #2 of 8 (permalink) Old 10-2-2013, 8:14 AM
fog
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Re: How to drill out the pilot screw cover

Drill a small hole anywhere in that cover It's less than a 1/16 thick alum and you won't hurt anything under it (A brass screw down rather deep) stick an Ice pick in the hole and lever the plug out.

Walla!


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post #3 of 8 (permalink) Old 10-2-2013, 9:18 AM Thread Starter
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Re: How to drill out the pilot screw cover

Thanks FOG Wish me luck.
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post #4 of 8 (permalink) Old 10-2-2013, 8:38 PM
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Re: How to drill out the pilot screw cover

Run a fine thread drywall screw into the cap, once it grabs use plies to pull on the screw.
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post #5 of 8 (permalink) Old 10-3-2013, 7:54 AM Thread Starter
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Re: How to drill out the pilot screw cover

I got the pilot screw out finally yesterday and cleaned it really well but problem persists :-(. View my other post ^
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post #6 of 8 (permalink) Old 10-3-2013, 8:13 AM
fog
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Re: How to drill out the pilot screw cover

That's only 1/2 of the job. You must pull the carbs and clean (Unblock) the pilot jets. They feed fuel to the pilot screws which only refine the flow to the engine.
Keep reading.

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post #7 of 8 (permalink) Old 10-3-2013, 9:05 AM Thread Starter
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Re: How to drill out the pilot screw cover

I drilled the pilot screw caps out and remove the screws out along with everything in the carbs and cleaned spotless. Spent 4 hours just cleaning carbs spotless.
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post #8 of 8 (permalink) Old 10-3-2013, 9:09 AM
fog
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Re: How to drill out the pilot screw cover

well you just wasted 4 hours of your time if you did not set the float heights ,back flush the line back to the tank and verify that the float valves are sealing. Did you also fit a inline filter.
Lot of honest efforts are undone by the lack of thoroughness.

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