PICTURES OF MY PILOT SCREW PLUG REMOVAL
Front cylinder carb pilot screw location
Rear cylinder carb pilot screw location
Seat off. Wrench is on bolt to loosen the gas tank.
Disconnected fuel connector and wood block under tank bolt to lift the seat. This gets you access to the intake boot clamp screw at the inlet of the front carb.
Disconnecting the throttle cables at the carb.
Disconnecting the emissions pod chrome cover.
Shot of the emissions equipment under the pod.
Disconnecting the hose and hose-clamp from the emission equipment.
Shot of the emission equipment hanging to the side. I couldn't get my hoses from the cylinders to come off so I laid the emissions equipment over carefully.
Draining the front carb.
Rear carb-intake boot removed.
Front carb-intake boot removed.
Disconnecting the choke cable at the carb.
Disconnected front carb fuel feed hose from the main fuel feed line.
Disconnecting the rear carb fuel feed hose from the main fuel feed line.
Loosening the outside front carb-outlet boot bolt. The bolt on the other side of this bolt is the first one to be loosened and it is kind of a pain reaching in from the other side to it.
Front carb-outlet stub boot. There is an o-ring on the other side of these boots that mounts against the cylinder. The groove for the o-ring has small indentions in it to help hold the o-ring in place. This helps tremendously when re-installing the boots.
Shot of the front carb with both its inake and outlet boots gone.
Shot of the front carb with the carb assembly removed from the rear-carb outlet boot, and the wrench on the inside bolt of the rear carb-outlet boot.
Wrench on the outside bolt of the rear carb-outlet boot.
Carbs out.
Carb assembly.
Showing plugs over the pilot screws.
Hand drilling to open the hole so I could feel how deep the pilot screw head was and to see how thick the plug was.
Plug removal with the large bit. Make sure you cover your carbs. I eased the drill on slow (real slow) and didn't push into the plug hard enough to shove it further in. It bites in and the plug starts spinning. Just pull the drill backwards away from the carb and the plug comes out stuck on the end of the drill bit. Let the drill rotate while you pull the plug out.
The two plugs. The plug on its face is the first one I removed using several drill sizes, thus leaving the counterbore in it. The plug on its side is the second plug I removed. On this one I went straight for the large bit after making a pilot hole. You can see the bite marks from the drill bit.
The carb assembly with the plugs gone.
Shot of bike getting ready to reassemble the carbs to the bike. The rear carb-outlet boot is shown installed but I had to remove it to get the carbs back through from right side. I had to play with and jostle both carb-outlet boots and the carb assembly to get it back together.
Plugs again.
Hand drill with tape marking the depth of the screw under the top of the plug.
