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Pilot Screw Cap Removal

Discussion in 'XJ Technical Chat' started by myselfnjit, Aug 27, 2007.

  1. myselfnjit

    myselfnjit Member

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    How do I remove these caps?? I could tinker but I figure you guys might have some great info.
     
    myselfnjit, Aug 27, 2007
    #1
  2. RickCoMatic

    RickCoMatic Well-Known Member

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    Hitachi Anti-tamper Plugs are thin and quite easily drilled through.
    Tape the end of the drill to act as a STOP at 2 or 2mm

    Mikuni Plugs are deeper. They are set so close to the Top of the Pilot screw it's hard to know when you've drilled through the Plug and start drilling into the Screw.

    I gave-up Drilling-out BOTH.
    Now, I grind them out with a Carbide Cutting Tip until they are so thin they are like Foil and can be peeled-out without damaging the Top of the Screw.

    If you have to "Take" a little-bit of the Aluminum surrounding the Plug ... that's OK. The Threads are still 3 mm below the Bottom of the Mikuni Plug -- BUT, the Screw is practically touching the bottom of the Plug.

    Brush on some Vegetable Oil and heat it up GOOD to get the Oil to seep into the groove. It helps in a BIG way.
     
    RickCoMatic, Aug 27, 2007
    #2
  3. Hvnbnd

    Hvnbnd Active Member

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    I just use a 1/16" but to start a hole (be careful not to mess up the screw)
    Then I start a screw into the hole then using pliers I pop the little cap out.

    That's It!

    Piece of cake!

    I have also used an awl point in the hole to pop the cap out too.

    Good luck there
     
    Hvnbnd, Aug 27, 2007
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  4. RickCoMatic

    RickCoMatic Well-Known Member

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    Some are a Piece 'O Cake.

    Other's are a Frustrating time for the Owner.
    I've had a set of Carbs come-in with broken-off drill bit through the Plug and part-way into the Pilot Screw, broken-off almost flush with the Carb Top.

    Tape the bottom of the drill so that don't happen; again.
     
    RickCoMatic, Aug 27, 2007
    #4

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