Carb rebuild woes

So I was reassembling the carb rack after replacing the throttle shaft seals and fuel orings. Everything was going great till I tried screwing in this screw, no matter what screw and how much I tried to force it straight the screw would go in crooked. I have no clue how, this is the first time its every been removed. Anyone know a good method to tap new threads? Also I noticed the idle screw does not reach carb 3's little handle that the screw pushes on. When the idle screw is screwed all the way in it still does not reach, WTF. I knew shit was going to easy.

 

early xj650 carbs only had 1 screw on bracket you could get away with onlt using 1 screw.

chacal may have thread fixing taps.
next option is to use threaded inserts

 

Is that bit of of right-angle rack bracing on the right way around. What if you loosen all the other screws before attempting the crooked one. Maybe you need to enlarge the hole in the angle for that one screw. If you've buggered the thread then you could try just running a tap down it
and using loctite.

 

Try another screw in that position , or find a thread chaser in that diameter metric . Or go to Harbor freight and buy a metric tap and die set.

 

That would bother the hell out of me knowing its missing one screw, lol.

I tried it when all the other screws were loose and with different screws, I guess I'll be tapping it, anyone know what size tap I would need? What bout the idle screw? Is it possible to orient the the throttle shaft wrong and cause it where the idle screw can't reach the throttle lever?

 

I attempted bench syncing the carbs, will have to try again later since I ran out of time. I followed a guide here on the forum and it said to tighten down the sync screws all the way before starting. When I did this the butterfly became difficult to open and close but when I loosened them up some they opened and closed freely. Does this mean there is an issue with the assembly?

 

Probably not when you move it in all the way the butterfly should move up , and backing off down . I just pulled mine and bench synched due to me not leaving well enough alone , personally I use 2 business cards cut in two with one under each butterfly , adjust each synch screw till you get a little resistance drag on the card , do final with idle knob it will get you close. I then after carbs put back on , I use a 4 vacuum gauge to get a running synch , I went thru mine again it runs well and has a good power.

 

I managed to get the carbs bench synced pretty well tonight, now beginning full reassembly to go back on bike. YAY