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TOPIC: Stripped carb boot screw

Stripped carb boot screw 30 Jan 2019 18:51 #797941

  • ERIK814
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Got three off no problem. Then the fourth slipped right as it started to turn and bam, stripped. There is a small amount of grip but then the screw starts to cam out. I don’t want to make it worse, so what next?
1982 KZ 440 LTD Belt Drive
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Stripped carb boot screw 30 Jan 2019 19:06 #797943

  • 650ed
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It looks to me like you tried to removed the screws using a Phillips screwdriver. They are NOT Phillips screws, they are JIS (Japanese Industrial Standard) and Phillips screwdrivers will not fit the properly (see images below). If it was mine I would first soak that screw with Kroil for 3 days. Kroil will break the bond between the screw and the cylinder head. While it is soaking I would buy or make a JIS screwdriver tip. The tip should fit perfectly, otherwise the odds of the screw coming out are very slim. Ed









1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)
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Stripped carb boot screw 30 Jan 2019 19:06 #797944

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Pick up a hand impact driver, Use the best fitting bit, Tap on the bit to clean up the slots then drive it out. If you have to take out the air box then do it.
Steve
Z1b1000 1975 Z1b
Opinions expressed by me do not reflect those of the the staff or members
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229
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Stripped carb boot screw 30 Jan 2019 19:24 #797945

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SWest wrote: Pick up a hand impact driver, Use the best fitting bit, Tap on the bit to clean up the slots then drive it out. If you have to take out the air box then do it.
Steve



I picked up one of those *mumble* years ago, and love it. It's the kind of thing that if you need it, you need it.

The drawback in this situation is there may not be enough room to get the impact driver in there straight and centered and still get a good whack at it with a hammer. I have a twin (440) with the same issue, and right now I'm just planning to pull the engine because there's no room to operate.
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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Stripped carb boot screw 30 Jan 2019 19:40 #797950

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I have been soaking with liquid wrench for about 5 days (4 applications over that period). Also used a vessel JIS #3. Photos attached. I definitely don’t have room for an impact driver without taking the air box out. How hard is that? Any other tips?
1982 KZ 440 LTD Belt Drive
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Stripped carb boot screw 30 Jan 2019 19:46 #797951

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I never attack those screws without a hand impact. I reinstall them the same way. Taking the airbox out shouldn't be that difficult.
Steve
Z1b1000 1975 Z1b
Opinions expressed by me do not reflect those of the the staff or members
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229

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Stripped carb boot screw 30 Jan 2019 19:50 #797952

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ERIK814 wrote: I have been soaking with liquid wrench for about 5 days (4 applications over that period). Also used a vessel JIS #3. Photos attached. I definitely don’t have room for an impact driver without taking the air box out. How hard is that? Any other tips?


In that case you have been taking the correct approach. Maybe removing the airbox will help. On my KZ650 that was pretty easy once the carbs were removed On mine there were 2 screws (one on each side of the airbox) that were sort of hidden behind the side covers. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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Stripped carb boot screw 30 Jan 2019 19:56 #797953

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Use some needle nose vise grips! Seeing you soaked it. Or use an impact!
That's an easy one!
Livin in "CheektaVegas, NY
Still have a Kaw! 76 KZ900 Pro-Street.
Went thru 25 of these in 40 yrs.

And The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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Stripped carb boot screw 30 Jan 2019 20:13 #797954

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Vampliers should work. They're also sold under the brand name Engineer. Anyone who appreciates fine quality tools will be pleased with either. We bought the three piece Vampliers set, but this individual plier should work for that screw.

www.amazon.com/Vampire-Professional-Tool...VT-001/dp/B006YJKAPQ


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Good Ridin'
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A Rider looks at your odometer and tags.

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Stripped carb boot screw 30 Jan 2019 20:34 #797955

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Did you get the bottom screw out. If so you may be able to drive the flange to the right to loosen the screw.
Steve
Z1b1000 1975 Z1b
Opinions expressed by me do not reflect those of the the staff or members
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229

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Stripped carb boot screw 30 Jan 2019 20:35 #797956

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slmjim+Z1BEBE wrote: Vampliers should work. They're also sold under the brand name Engineer. Anyone who appreciates fine quality tools will be pleased with either. We bought the three piece Vampliers set, but this individual plier should work for that screw.



Just ordered 'em. If they work I'll owe you at least a beverage or two. :)

The PO of my 440 said there was an intake leak so he used what looks like a full tube of silicon to try to seal around the boots. I'm replacing the carbs and the boots and removing the airbox, so the only real concern is getting the boot screws out without jacking up the head.
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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Stripped carb boot screw 30 Jan 2019 23:23 #797957

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Cut a slot with a Dremel and use a straight screwdriver ( helped by vice grips on the shaft ). Impact driver would be best though.

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Stripped carb boot screw 31 Jan 2019 06:27 #797962

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SWest wrote: Did you get the bottom screw out. If so you may be able to drive the flange to the right to loosen the screw.
Steve

What Steve said.

You indicated the screw had indeed rotated.. Heat and additional grip might help too.

Getting the port area around the stuck screw good & hot can help relax the bond between the threads. A HF heat gun is a relative bargain and can pay for itself many times over. Even on something as massive as a head we've never had to run ours more than ten minutes on low to get the target area hot.

If you have any sort of powdered abrasive paste such as valve grinding compound, dipping the tip of the bit in it will help the bit get a better purchase in the damaged screw head. Pumice used to make paint grippy for use on steps & porches can be used too but don't use it dry, or it might get in places it shouldn't be. Mixing pumice with toothpaste will keep it under control and is water soluble.

If those don't work, a helper would probably be necessary. Steve's concept is to rotate the boot CCW around the stuck screw while at the same time applying CCW twist to the screw with a bit. The helper could be on the left side of the bike with an extension made of something relatively soft, like an appropriate length of 3/8" wood dowel or similar. Brass rod maybe, if great care is taken to not strike the outside of the port itself.

Have the helper place one end of the dowel or rod as low as possible on edge of the lower flange of the boot itself. Next to the empty screw hole would be ideal, but not touching the outside of the port itself. While you are applying CCW twist to the screw with the bit or Vampliers, have your helper tap the other end of the extension to rotate the bottom of the boot CCW around the stuck screw. The boot may be reluctant to move at first because the rubber will have molded itself to the shape of the port's lip. If you look at the boot you've removed you'll see what we mean.

Be patient & tale your time. Gentle persuasion is called for here rather than outright force.


Good Ridin'
slmjim & Z1BEBE
A biker looks at your engine and chrome.
A Rider looks at your odometer and tags.

1973 Z1 x2
1973 Z1 "The Wounded Z" Resto project
1974 Z1-A x2
1975 Z1-B x2
1993 CB 750 Nighthawk x2
2009 ST1300A

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Stripped carb boot screw 31 Jan 2019 06:57 #797963

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Vice grips on the side of the screw should get it. Also, do as Steve suggests and try to rotate the boot CCW. Many times doing that will cause the screw to rotate along with it.

Another technique which is to take a sharp chisel with the edge on the perimeter of the screw and give it good whack causing the screw to turn. I've had good success with this.
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Stripped carb boot screw 31 Jan 2019 07:16 #797966

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I never use locktight on cover fasteners. If the PO did heat is the only answer.
Steve
Z1b1000 1975 Z1b
Opinions expressed by me do not reflect those of the the staff or members
kzrider.com/forum/11-projects/598262-kz-...-will-it-live#672882
kzrider.com/forum/2-engine/597654-poser?start=240#704229

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Stripped carb boot screw 31 Jan 2019 17:05 #797994

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Ordered a pair of the vampire pliers and will hopefully get this sucker out. Until it arrives I'll plan on keep applying liquid wrench and see if twisting the boot helps (it is the top fastener that is stripped). I could have sworn the bolt moved a bit before the bit slipped /stripped but maybe it was just my imagination.
1982 KZ 440 LTD Belt Drive

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Stripped carb boot screw 31 Jan 2019 17:57 #797996

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Take the bit and hit it with a hammer a few times to reshape the slots then try to twist it out.
Steve
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Stripped carb boot screw 31 Jan 2019 18:29 #797997

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Vice grips are much stronger than those Vampire pliers.

Edit: this photo is just a mock-up but it should give you the idea. Clamp onto the side of that screw as tight as you can and then turn the screw out.


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Stripped carb boot screw 31 Jan 2019 20:09 #798004

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Okay, I'll see if I can find some vice grips.

In the meantime, I plan to purchase new bolts. The bolts are 6mm x 15mm (almost exactly) but I don't see that size available on Z1. Instead they have 16mm and 12mm. I assume the 12 is the way to go but just want to confirm.

Thanks!
1982 KZ 440 LTD Belt Drive

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Stripped carb boot screw 31 Jan 2019 20:52 #798005

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ERIK814 wrote: Okay, I'll see if I can find some vice grips.

In the meantime, I plan to purchase new bolts. The bolts are 6mm x 15mm (almost exactly) but I don't see that size available on Z1. Instead they have 16mm and 12mm. I assume the 12 is the way to go but just want to confirm.

Thanks!


I would NOT buy bolts that are a different size than the originals. There are plenty of places out there that sell metric bolts & screws. Take a look at www.kawasaki.com/Parts/PartsDiagram/135173/1982/KZ440-D4 It looks like the screws you need are part number 220B0616 (220A) - they are 6mm x 16mm. Notice the link below has 6mm x 16mm machine screws for .08 cents each. I'm sure there are other places that also have exactly the size you need. eBay has them too - see Ed

BOLT DEPOT

www.boltdepot.com/Metric_machine_screws_...eel_6mm_x_1.0mm.aspx
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