Bonneville America Forums Forums Technical Forums Exhaust Air adj cap removal ?

Need to make an adjustment, to elimate popping, after installing new Thunderbike pipes. But don't want to remove the carbs. Is it possible to remove the cap(s)to get to the air adjustment screws ? With the carb(s) still on the bike. This is on a '03 TBA, without the "D" style plug(s).

yeah it is. I did it, but didn't have a great understanding at the time. I actually drilling into the SIDE of the housing for the screw because I thought that whole boss was supposed to come off when actually it is a cap recessed within that boss that pops out. I have a set of drill bits with hex shanks, that helps a lot cause you can slip it into a ratchet and drill up that way, or even by hand. I reccomend a tiny pilot hole, then a wood screw to yank it out.

I used a 1/8" drill bit in a right angle dremel attachment. Use what you can to get a hole in the cap and then screw in a drywall screw and it doesn't matter if you bugger it up. Then grab the screw with a pair of pliers and rip that sucker out.

I actually had to do this a couple of times as the screw kept popping out...

its really soft metal. I took a drill bit and just twisted it with my fingers to make the pilot hole for a screw. Then just insert a screw and yank them out.

Yeah the metal on these carbs will get chewed up REAL easy, be especially carefull with the float bown screws, especially the ones that also hold on the idle adjustment.

Right, it's pretty soft metal like Trash says. I took mine out with 1/4" hex head sheet metal screws. That allowed me to use a 1/4" drive ratchet and socket to drive the screw into the plug. It took a couple tries, but it works. There is also (at least there was on mine) a small dimple in the center of each plug, making it easier to get the screw started. Use a small mirror and flashlight to check out your "targets" from under the carbs.