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Carb bolts

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deepdiver

deepdiver

Active Member
I am working on my #2 '95 SPX. As you know the carbs have M8x75 bolts with a 6mm Allen head. I searc'hed and read about how to get those bolts out and tried..PBblaster, slow back and forth, etc. but screwed it up by getting a bolt out past the threads but still stuck. I then tried to pry it while turning with a 6mm socket but it slipped and tore up the hex, Thought I'd just turn it back in but no way. So now stuck. Two bolts out of four in two carbs still in fully. One out completely and the other out 3/4" as above. What do I do now? I'm inclined to just put the air header back on and try it out. Really would've liked to clean out the internal carb filters which was my goal. Now planning to replace all the fuel lines plus already replaced gas/water filter and clean out of fuel tank..
Anybody have any luck with EZ-OUT's? :mad:
 
Trying to pound from below sounds good but I know there's not much room in the SPX to pound from. I'll give it a go. Thanks Seadooya..
 
thought you said, carbs are out, just the bolts are stuck in the carbs' passages?
 
No I said "Two bolts out of four in two carbs still in fully. One out completely and the other out 3/4" as above." So I've got one bolt still fully in each carb, one out, and the other partially out which has the hex socket reamed out somewhat so can't turn either way. The two in full don't want to move but the hex socket heads aren't too bad.
Sorry for the poor wording. I haven't gone back to it yet.
 
If you have 2 of the 4 bolts out, but are now in the carb, the carbs will still come off and then you can get them out of the carb body on the bench. Work on the other two bolts to see if you can get them out - be careful of stripping the heads...

If you mess the whole thing up, you can always buy a replacement rotary cover and new bolts.
 
Now all the remaining three bolt heads are reamed out. The engine runs Ok as long as I manually feed gas with a teaspoon direct into intake. Appaently fuel pump diaphragm is bad. Maybe messed up when I tried heat on bolts. Took to a welder to have nuts welded onto top of bolts and he declined, worried not enough room to do it properly. Recommended getting engine out of ski. Can I get it out with carbs still on after removing drive shaft,pump, exhaust and Rotex cover?
 
Thank you. I now have two recos to junk the carbs and intake. I'm willing, but no one says how to get them off. I did ask if it is possible earlier. The bolts holding the intake seem to be blocked by the carbs. Maybe I'm missing something.
 
Thank you. I had just sat down to look at the manual. I assume that is same as I have in Service manual and it will also have a section on removal.
 
An update: Well it worked but it was a bitch. Got all the bolts holding the whole oil pump off. Actually the two in the forward end were very difficult... but patience won out. The last, top one, pushed the whole acrb assembly out since it was jammed against the carb. Oil pump cover hex heads are inaccessible with carbs on. Luckily the bolts were sorta loose.
Now to take it to a mechanic/welder. Either drill out bolts and use extractor or weld a nut onto top of the three remaining bolts. They wouldn't budge with vise-grips.
If this fails have to buy replacement parts.
 
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Update on carb bolts

My welder/mechanic tried evrything above with not much progress. He ended up cutting the heads of the bolts off. Difficult for sure with stainless.
So I was left to drive the bolts down and out. Seems straight forward but these bolts are really tight inside the carb. After separaing the carbs, the threaded part is loose. so after rotating the carbs I could put the carb base on an edge and pound the bolts. Finally got one bolt out, the other had been previously unscrewed but was still frozen inside. So that carb is now separated from manifold. However the other remining bolt just wont budge after driving it down about 1/2". I am driving with a 1/4" bolt and have bent them wihout moving the stuck bolt. But I am going to continue, soaking using PB Blaster and hope to break it loose before Spring, wishing you all Happy Holidays.
 
Ugh...

You know with all the $$ you've spent with the welder and the hours you've wasted on this, you could've bought the parts used and had the ski on the water already....

This is a common issue, and it's just easier to replace the parts, post a wanted request at one of the larger pwc boards for those parts or ebay.
 
Thanks parrothd and that's still an option. My time is cheap since I'm retired with not a lot of other stuff to do. The prices on the used stuff is not cheap from my research. And the welder only cost $20, whereas the used parts, (two carbs, intake manifold, and oil pump, and bolts) would be at least $200. And putting into the water is still 5-6 months away.
 
K,

But be aware those intakes pieces are very fragile and break easily, with all the "work" you've done on them don't be surprise next year when you seize your engine because the intake cracks and causes a lean condition totaling your motor.. :)
 
I am happy to report I was able to drive the remaining bolts out. The carbs were separated during the process. Looks like fun getting those spring loaded throttle and choke link connections back together. Cleaned out both carb filters but they weren't completely blocked. Wonder why the fuel pump wouldn't pull gas from the tank... either bad diaphagm or air leak I guess. Diaphragm looks OK.
 
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