Hi all,

One of my idle adjustment screws was frozen in place, so I soaked it with PB Blaster. Unfortunately, I still broke it trying to get it out. Is there an accepted method for getting it out without damaging anything? Thanks for any suggestions.

Roger

Check this out

Scott, You are worth every dime we should be paying you!

Thanks very much, Scott. So, there's no problem with leaving the hole there? I suppose it will be covered by the gasket, so should not leak(?).

Actually drilling doesn't solve the problem,the broken threaded part is the problem,still there and not easy to remove.If you try drilling,you have about one chance in ten of drilling dead center without a jig and if you don't then you end up drilling the threads.At that point the alternative is make a new insert for the base.

62max has a good idea, but I actually had this problem myself about 2 yrs. ago & used Scott's drill method & a propane torch I believe and was able to get the outboard idle screw out. It may have helped that I'd only broken off half the head of the screw.

My 2-cents.... try the drill method & if that fails, go with 62max's idea. What do you have to lose?

Hey 62max....HOW DID YOU MAKE THAT NEW INSERT.... I (we) are all ears.

fortunately I had access to an EDM machine when one broke off.

I ended up doing what 62 max did. I drilled out broken screw part. Then enlarged it to 1/4" (used slight undersize ream from McMaster Carr. Inserted 1/4 aluminum rod about 1/2" if I recall. drilled and tapped for new screw. I ended up having to do all four. I had one that was ever so slightly off center, but didn't seem to affect performance. At least as good as I had the tune I could get.

A little addition if you try to remove broken screws by yourself.First thing you need to do is get rid of the old cork seal,either heat or pick it out.The seal is the creator of the problem,over the years it turns rock hard and makes removing almost impossible without breaking.If I get three sixpack set to do I can guarantee at least two broken screws minimum.Also if you choose to drill,a small end mill is almost a necessity,unless you have a perfectly flat surface to drill,the drill bit will walk and not center.Once I get them drilled,I use a small center punch with the end squared,tap it into the hole and back the screw out,picture attached.

I like this drill, square punch idea.