Stuck pilot jet.....

[Mikeyc]

I am rebuilding my carbs using the tutorial, including the new o-ring kit. Everthing is going extremely well, except I can't get the pilot jet out of Carb #2. Despite taking all of the necessary precautions (correct screwdriver, lots of liquid wrench) I can't get the pilot jet out and the top of the jet is damaged (galled by the screwdriver). I think the pilot jet is just fine in terms of being cleaned by the dipping process and blowing compressed air through the jet. My plan was to simply leave the jet in the carb body as-is and continue on. Does anybody have an opinion on this plan?

[tkent02]

Might work, might not. It depends on how badly the tiny passages in the carb body are clogged. You can't really clean them with the jet in place. If it ran OK before you might get away with it.

[Mikeyc]

What are my choices? The carbs seemed pretty clean to start with.....I may just take the chance and continue with the pilot jet stuck in the carb body.

[buster]

I was lucky enough to be able to use a extractor and get my stuck pilot out, but I'm told it was a VERY lucky try. I just picked the smallest one in the set and ran it into the pilot hole and it came right out.

Best of luck to you either way!

[hikermikem]

Stuck pilots can be a real PITA. As Tkent says, you can't do a proper clean without removing them...

Here's how I get them out, even after munging up the head pretty good:

- The single most important thing is to have a screwdriver that fits that slot fully, meaning the width of the blade needs to be the same as the width of the slot. Use one of the pilots you've removed to find a screwdriver that fits perfetly (go buy a new one if you have to).

- Then grind down the sides of the "perfect" scredriver so it fits down that little hole the pilot jet is currently held captive in.

- Mix a small batch of 50/50 ATF & acetone. This is a GREAT penetrating soultion. PB Blaster is OK, but this stuff rocks IMHO. Squirt liberally down the hole & let sit for a bit (couple hrs??)

- Make sure the carb body is stable & sitting on a hard surface. Insert your "modified" screwdriver & apply pressure in the loosening direction.

- Now give the handle end of the screwdriver a very solid whack with a hammer. If it doesn't break free after a couple of good whacks, apply more ATF/acetone solution - try again.

- In extreme cases, I've had to use a torch to heat the metal adjacent to the pilot jet - just take care with the torch, the acetone is flammable.

Good luck,

mike

[hikermikem]

I was lucky enough to be able to use a extractor and get my stuck pilot out, but I'm told it was a VERY lucky try. I just picked the smallest one in the set and ran it into the pilot hole and it came right out.

Best of luck to you either way!

Yes, you were extremely lucky - if you think a stuck pilot is bad, try one with a snapped extractor in it!! You'll be looking for a new carb body in no time...

Glad it worked for you, but my luck isn't so good with those things.

[Mikeyc]

What to do, what to do.......gamble with leaving it as-is.....or risk damaging the carb body????? Hmmmmm.

[tkent02]

Not much of a gamble, all you risk is having to take the carbs off again. If it ran fine before, that passage must have been fairly clean. Spray carb cleaner through the jet, does it come out all the same places as it does on the other carbs? If so you are probably OK. Have you buggered up the screw enough to seriously effect the flow of fuel though it? If so you may need slightly different fuel and air screw adjustments on that cylinder, no big deal.

Are these CV or VM carburetors?

[Mikeyc]

Thanks tKent.....that is what I was thinking. The other jets were all clean. I did not damage the jet badly.....I stopped trying to get it out when the screw top first slipped. The hole in the top is fine and when I sprayed carb cleaner followed by a burst of air....it came out strong.

[Mikeyc]

BTW......they are CV carbs from an 82 850 GSL. Thanks for the replies!

[hampshirehog]

Use good quality penetrating oil (not WD40 or anything less), let it soak, select a good fitting screwdriver and give it a sharp tap as you twist. These things shouldn't get too badly jammed in as they're brass in pot metal.

[chef1366]

One of the few things I do use Never Outs on is stuck pilot jet.
Drill the jet since the hole is already centered.
Heat the carb body around the jet.
Use favorite lubricant I like PB Blaster
install Never Out and it should break free.

Never Outs = Easy outs