Removing broken pilot jet ???

[zwoodman]

I am rebuilding the carbs on my GS850GL, but when I got ready to remove the last pilot jet, I could tell right away it had been damaged. The slot is basically broken off. I'd be grateful for any tips on how to get it out.

I'd much rather be in the wind today...

Mark S.

[Walle]

Feel the inside of the carb venturi. If the tip is peeking through you can push it back out with something that wont damage or scrabe the carb. Like an old rounded off screwdriver. Worked for me when I discovered 3 tips lodged in there.

[Nessism]

I suggest using heat on the carb body and seeing if you can get the jet to turn using a screwdriver crammed down into the jet. If that fails I don't know of any other method other than a screw extractor. It's very easy to break off the extractor in the carb so you need to sharpen your touch and not force anything.

Good luck and hope you get it out.

[zwoodman]

Thanks, but I'm not sure we're on the same page... I don't see anyway to get to the other end of the pilot jet. If you look at pages 33-35 of John Bloemers carb clean up PDF, you'll see the small brass jet I am refering to. Forgive me....I am "zwoodman" not zmotorcycleman if it was made of wood I'd have no problems....

[zwoodman]

Thanks Ed, I'll give that a try. I have some screw extractors, but nothing that will fit down that hole, I assume they'll have something at autozone or pepboys.

I ground an old screwdriver to make sure I had a good fit, before I started...it worked great on the first three, too bad there are four of them. I bought the bike from an old friend and suspect I know who damaged the jet....I can't wait to talk to him !

[1948man]

Maybe a small left-handed drill bit.

[zwoodman]

GOT IT !!!! I drilled it VERY carefully with an 1/8" bit then heated the body with my heat gun and finally used a 1/8" screw extractor...Thanks to all for the advice !!!

[zwoodman]

I found new jets at http://www.bear-motorsports.com/ for $3.75 ea. So, 4 of them plus shipping was only $20 bucks. My local dealer wanted $10 ea. I let you know after I get them how good the quality is....