Pilot jet is stuck help me!!

[Kitten Tooth]

Right now im working on a bike for somebody. You ever have a day where everything goes wonderful when you working on something and the very last thing you do, something totally haults you in a big way? well, thats what happened to me. I was working on the last carb on this 1981 GS650G. I put my flathead screwdriver in the hole and made sure it was centered in there perfectly. I slowly began to apply pressure and the screw driver slipped (Later on i had found that the end of the screw driver had twisted). I didnt know this and i thought that i simply offcentered it while i was trying to turn the jet out. It slipped again and there went the little slit for the flathead screwdriver. Theres no way to turn out the jet now with a screwdriver that i have found so far. Its like the metal where the screwdriver fits in is crumbled off or something. When stuff like this happens, how do you guys get it out? The jet is receded in there quite a ways..

[almarconi]

I would try PB blaster and some heat. If the head of the jet is completely buggered up, try a left handed drill bit and very carefully drill it out. Hopefully the PB blaster will loosen it enough that when you run the bit into it, it will turn right out. Worse case scenario, replace the carb body.

[bluewool]

Right now im working on a bike for somebody. You ever have a day where everything goes wonderful when you working on something and the very last thing you do, something totally haults you in a big way?

That's the story of my life, but there's always a solution.

1 Why do you need to remove it?

soak it with carb cleaner, clean it with a strand of copper wire, blow it out with compressed air and leave it in there.

2 Risky, but , a small narrow easy out, really careful and gentle or you're buggered.

here's the advrider solution http://www.advrider.com/forums/showthread.php?t=439001

hey it's exactly what I said strange, like I've read it when it happened to me or something. anyway. the left handed drill bit is likely number 2 to bump the easy out to three, either way if they break you're probably replacing the carb body.

[Steve]

OK, exactly which "jet" are you trying to remove?

The only three that live in recesses are the pilot air jet (the one that is in the 8 o'clock position in the carb intake),
the pilot fuel jet (the one in the float bowl, next to the main jet and under the rubber plug),
and the idle mixture adjustment screw (the one on the top of the carb outlet).

The pilot air jet is not that critical. It's rather large, and does not have fuel going through it to gum it up.

The pilot fuel jet is critical, but I have seldom seen them too tight to remove.

The idle mixture adjustment screw is quite often stuck, because it can sit in the weather and hold water on top of it, which then promotes corrosion.

If that is the one, the solution is rather simple. Use a large cut-off wheel in your Dremel tool, cut a slot down the middle of the 'tower' and cut a new slot in the top of the screw.
Should look a bit like this: (both #1 and #2 have had slots cut into them)


.

[Kitten Tooth]

It is the pilot jet in the bowl area next to the main under the rubber plug.

[Kitten Tooth]

And what is PB blaster? can i get it at an Advance Auto store?
Thanks guys,
KT

[Texasgs]

re

PB is a penetrating lube, but I think you are pretty far past that. You need to stop and think about this, and how bad you want to get that jet out. If you have to jet the bike there isn't much choice, but if you are rebuilding the carbs just leave it in. Use some berrymans chemdip to clean it and it will take out any fuel deposits. If it is unstopped it doesn't matter if it is stuck, the carb will work perfect with a stuck pilot.

The reason I suggest leaving it in, is if you go any farther you might destroy the carb body, and you will destroy the jet. If it has to come out drill it and use an easy out. Soak it in oil over night before you use the easy outand just before you put the mojo on it hit that area of the carb body with heat, aluminum expands much more than brass, and it can help it to break loose.

[blowerbike]

an easy out and a little propane heat has never failed me.
could bad things happen..? YES.
so far...so good for me.

[tom203]

I would try PB blaster and some heat. If the head of the jet is completely buggered up, try a left handed drill bit and very carefully drill it out. Hopefully the PB blaster will loosen it enough that when you run the bit into it, it will turn right out. Worse case scenario, replace the carb body.

Yeah, this usually works for me as long as drill bit is not too small.
But I think the novices need to understand what the left handed bit is doing. The jet is screwed in with a right hand thread, so when you drill it with a left handed bit,when the bit grabs it, it's naturally backing it out. Just be careful!

[hikermikem]

It is the pilot jet in the bowl area next to the main under the rubber plug.

I've had terrible luck using the easy-out stuff but to each his own.

Here's how I get them out, even after destroying 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). The jets are brass so a nice sharp screwdriver end will bite into the jet.

- 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

[woodman]

Some one on the forum suggested a Snap-on screw driver #SSDE64D. I bought one, ground it down a little and it really works, the fit is great. They aint cheap though like anything else snap-on, $15 but its worth it.

[blowerbike]

my easy out suggestion requires heat also.

[Texasgs]

re

A few things about some of the comments. If I am reading the post correctly, the pilot screwdriver slot is trashed, and the screwdriver slot is done. So if the fat lady has sung on the screwdriver slot, we are way past god level screwdrivers specially ground to fit a slot that went south. So that is why I said that if it can stay in clean it and leave it if you are not good wit getting things like this out. You could trash the carb body in a heart beat.

Using an ease out in brass that is stuck in aluminum is normally a very good solution, baring any complications. Complications like, drilling the hole to big, drilling to deep, twisting off the the pilot, and probably some I didn't list. It isn't that it is so hard, I am just saying that be aware of the risks, and get ready, remember Murphy's law. What ever you do good luck.

[chef1366]

an easy out and a little propane heat has never failed me.
could bad things happen..? YES.
so far...so good for me.

This is a good method. I usually don't use Never Outs but in this case I do with heat.

[Kitten Tooth]

yea, im liking the sound of the left handed bit.. i think thats just what i need. You see, i had disassembled everything and cleaned it all up really good. I had some concers about the seats and how messed up they were on the insides. I was hoping the needles wouldnt stick in there. when i re-installed the carbs in the manifold boots and supplied fuel to the carbs, i gave it a crank with the starter and it sputtered a little bit but wounldnt fire. So, i pulled the drain screws out and no gas poured out... So i took the carbs off again and found that the needles were totally stuck in there. So i gave the guy a call and told him to just order the kits. He said he would get ahold of me on monday. So i figured i would disassemle them again and spray out all the little ports and everything when i put them back together the first time, its not like i screwed them in with super-human strength or anything, i just seated them nicely. On the last carb, i pulled the rubber plug that was covering the pilot and put my screwdriver in. Everything was going great until the screwdriver slipped the first time.. i didnt know the driver was damaged so i figured i would keep trying. Low and behold, the slot in the pilot jet is messed up. That left handed bit should pull it right out. I dont feel comfortable with using that jet in there, so im going to replace it. Thanks for all the replies guys. Ill post here some more if i got and questions.

THANK YOU ALL!!!
KT