Drilling air/fuel caps - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 9 (permalink) Old 03-03-2010, 12:50 PM Thread Starter
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Drilling air/fuel caps

can anyone tell me if it is possible to drill out the lead cap over the air fuel screw without first pulling the carbs?

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post #2 of 9 (permalink) Old 03-03-2010, 04:09 PM
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have to pull the carbs
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post #3 of 9 (permalink) Old 03-03-2010, 04:12 PM
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I used a file to scrape a notch in the plug, then I pried it off. My vote is no pull needed.

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post #4 of 9 (permalink) Old 03-03-2010, 06:27 PM
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I used a small hand drill, not a electric drill, more control. Then pried them out with a steel pick, a small screw driver may also work. Then you can reset the air mixture screws. Turn them in slowly,clockwise, carefully seat them lightly, then turn them out. Count the turns to 2 and a half turns at first to see how it sounds.

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post #5 of 9 (permalink) Old 03-03-2010, 10:28 PM
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i concur with the above reply. I used a small drill bit...once i broke through i stopped. I then used my dental pick to pry the lead plug...no probs.

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post #6 of 9 (permalink) Old 03-04-2010, 12:56 AM
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I also got them out with out removing carbs. I think kimmer has the best idea.

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post #7 of 9 (permalink) Old 03-05-2010, 03:24 AM
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No need to remove the carbs, they are right on the side, easy to get to. I would suggest using extreme caution though. 2 really bad things can happen. One is you can drill right through the caps and destroy the mixture screws, and possibly bugger up the screw threads in the carb body, you can also break a good sized chunk out of the carb casting trying to pry them out. Take your time. I first took a tiny and very sharp punch, and a hammer, and made a dimple in the very center of each cap, so the drill bit wouldn't wander, then used a very small drill bit to drill most of the way through the plugs. I switched back and forth between the drill and the punch a few times, until I got all the way through. I then used a slightly bigger drill bit to make the hole bigger, and screwed a self tapping sheet metal screw part of the way into the hole. I then used a hair drier to heat the area while I wiggled the screw till the caps came out. Sounds like a lot of trouble, and it was. But I didn't break anything. These caps are GLUED in place, with something similar to super glue. It is very easy to break the carb casting trying to pull them out. Some extra time and patience here can prevent some very expensive damage. Jerry.

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2006 Sportster 1200 Low
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post #8 of 9 (permalink) Old 03-05-2010, 08:48 AM
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Rather then drill mine out I screwed them out. *L*
The material is lead, so just tap a long fine screw into it to get it started, turn a few times to give it a good grip in the lead, sort of like setting a handle into it and I was able to pop mine out with a set of pliers to the long screw.
No need to pull the carbs, the air mix screws are located here..
Left side


Right side

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post #9 of 9 (permalink) Old 03-05-2010, 02:12 PM
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That's what I did too. I just drilled a small hole in them to make it easier to get the screw started. Jerry.

I am a motorcyclist, NOT a biker.


1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike
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