Bandit Alley

MODEL SPECIFIC => SUZUKI BANDIT 600 thru 1200 - AIR/OIL COOLED TECHNICAL => Topic started by: NomisQC on October 03, 2007, 01:47:26 PM

Title: Drilling Pilot Screw Plugs Drill Bit Size ?
Post by: NomisQC on October 03, 2007, 01:47:26 PM

What is the correct drill bit size to drill the A/F mixture plugs out of a 2004 Bandit 1200 ?

I can't find the info as most people say "using the supplied drill bit" when they are talking about a Ivan or Dale jet kit.

Thanks !

Title: Drilling Pilot Screw Plugs Drill Bit Size ?
Post by: Red01 on October 03, 2007, 03:06:20 PM

Something big enough for you to thread a screw into to pull them out, or like I did and pop them out by cocking the bit (drill motor off) after breaking thru the plug. Something like a #40 or #30, IIRC.

Title: Drilling Pilot Screw Plugs Drill Bit Size ?
Post by: pmackie on October 03, 2007, 07:53:03 PM

I used a 1/8", but a 3/16" would have also worked. As Red01 said, something big enough to thread a small screw in.

On mine, two came out with the drill bilt only. Two needed a screw threaded in.

Oh...before I forget, wrap a few turns of tape over the drill bit, about 3/16" from the end to use as a stop. You don't want the drill too deep!!! This IS important...

Title: Drilling Pilot Screw Plugs Drill Bit Size ?
Post by: Red01 on October 04, 2007, 11:16:20 AM

I didn't use a stop, but then I have a lot of experience drilling holes since I'd done a lot of drilling in my days as an aircraft structure repairman before I got this cush job in QA.  :wink: