I was in the process of cleaning up my GS and redo of the carbs. I haven't posted in a while as most times I don't need help but now I'm in a pickle. I do have a second set of carbs but don't want to kill one GS thats running for another (Goal 2 running bikes). So i was doing a break down replacement and cleaning of the whole carb and i got to the air jets. knowing they would be stubborn i soaked. I am not talking about the pilot jet (I had no problem removing these) I am talking about the air jet on the front side of the carbs. Noting that my bike was a CA breed this means you have smaller air jets than the rest of the country. I figure why not give these a pop and swap.. Cleaning and soaking didn't not unlock and had to move to the next level. Under taking the screw driver tap as brass is displaced easy i gave a light tap with the hammer and set the Screwdriver blade. Then twisting the brass didn't move rather shaved the notch. So now the screwdriver climbs out when turned. ... Moving along with no way to re slot.I know I am at the point that I have to result to easy out. I have used many times before on other projects and decide no problem they should just back out.  So I drill out to easy out size and then proceed to break off easy out in brass.

Now rendering the air hole sealed and as easy out is harden steel so redrilling and helicoil is not an option?  Without a high end mill or an emd machine how can i get this easy out that is broken plus the air jet out. I really don't want to buy another set of carbs. I know I have though maybe JBwelding but fear that it will just bind up everything.  Anybody else have exp in this let me know.

Woweee ... I guess I need to leave my critical hat @ the door and not call you a fool huh ... OK.

Fine, put a pic up, the brass cap needs to be removed, not tapped and heli coiled.
Put a pic out. I may get you out of the pickle.

Cool.
Buddha.

Quote from: ignoreance on May 17, 2010, 02:29:44 AM
I am talking about the air jet on the front side of the carbs.

I don't think he's talking about the brass plug. 

I didn't know the AIR jets were removable.

see the easy out is broke of broke in the air hole. Yes this makes a difference in bikes you can look it up at your local dealer. Helps idle to 1/8 throttle and yes the are sevice and replaceable  you can get them from 8-12  bucks a piece i have done them on other bikes.

 

Quote from: ignoreance on May 18, 2010, 12:44:53 AM
see the easy out is broke of broke in the air hole. Yes this makes a difference in bikes you can look it up at your local dealer. Helps idle to 1/8 throttle and yes the are sevice and replaceable  you can get them from 8-12  bucks a piece i have done them on other bikes.

Who the Fsck asked you to remove these. You're not the first to pull these though. I've seen several ... and sadly, sorry my friend you're screwed. Cos you dont get replacements and worse yet, that piece your easy out is in, is pressed in not screwed in I think.

Buy a carb set.

Cool.
Buddha.

ouch... :-(

So....

Have you removed the air jet in the other carb yet?   

Please let me know what you do to fix, I tried to take mine out last carb cleaning.  left side came out easy but right side slot started to strip like you mentioned but i just stopped and sprayed carb cleaner before it got any worse. 

Yet another "Easy-out" disaster     the 2nd one this week, add it to the hall of fame 

Looks like the pilot hole might have been too big, the part has swelled out as the easy-out dug in and its become even tighter. EDM might shift the remenant but its very small. Smallest tap I have seen spark eroded was 0.125"  and there was no gaurantees. You will have to get a definative answer from the operator and he will want to take a lot of $$$$ off you and you will still have the original problem to deal with.

Probably easier/cheaper to find another set, ebay or breaker.