Pilot Jet refuses to budge!

[Guest]

82 GS650G

Im taking apart my carbs for cleaning.....everything is good except this damn Pilot Jet.....it's just stuck, and im pretty sure im starting to strip away at it!

(i had a hard time getting all the phillips-head bolts off the carbs the night before, but found a technique to get them off.....however i cannot do this for the pilot jet!)

I've tried carb cleaner and liquid wrench, no luck.

Should i just keep trying to soak it with liquid wrench over night?

Because the entire reason I took apart these carbs was because of an assumed problem with the pilot jets, and now I can't see if there's any potential crud in there!(which now im assuming there definately is)

Do you think i could just spray the hell out of it with carb cleaner and it will get rid of any junk down in there, INSTEAD of struggling with this jet.....before i end up stripping it or breaking it?


I also had trouble popping the Float Pin out, you're supposed to punch it out, but i feel like im about to break it, since it just wont pop out.


Any suggestions?
Can i get away with just spraying the jet and "hoping" it's clean under there?
Or is this something that must absolutely come out for inspection.


ANY tips would be helpful, im completely out of ideas.....not any room to do anything in such a tight area!

[almarconi]

Any suggestions?

ANY tips would be helpful, im completely out of ideas.....not any room to do anything in such a tight area!

I would suggest a good fitting quality screwdriver with a hollow ground tip. Spray some PB blaster in the hole and let it sit then remove the jet with the screwdriver.

As far a float pins go, I use a pair of side cutters to grip between the head and the post. Gently wiggle it back and forth to get the pin started. You can use a punch but make sure to support the float post (a small socket will work) before you hit the pin or you could break off the post. Another option is a utility knife blade between the head and the post. Twist the blade and this should move the pin enough to get pliers on it. Make sure to wear safety glasses since the blade can break.

[Nessism]

Yes, a properly fitting screwdriver is critical. I took an older one and ground it down on a bench grinder until is was a good tight fit. Soak with PB Blaster or similar, not WD-40 and the like, and use heat on the carb body. Heat it up using a heat gun or propane torch after you get those floats out that is. Speaking of that, the float pin is flared just under the nail head so that's the side that provides an interference fit. If you place the nail head over a small socket to support the float post on that side, you can drive the pin out with a punch and hammer. If you don't have a proper socket you can take a piece of wood, the idea is to support the post while pushing on the pin.

Good luck and take your time; stripped pilot screws and broken float posts need to be avoided at all costs.

[hikermikem]

I've had good luck removing stuck pilots by first soaking with PB Blaster for a day or two; then insert the largest flat blade screwdriver that will fit into the slot. Give the screwdriver end a solid whack or two with a mallet - you will ruin the pilot jet, but it should break free so you can unscrew it.

Call Z1 Enterprises to see if they have new pilots for you...


Regarding the float pins, take extreme care not to snap the float posts!!

Many here have had very good luck using spring loaded punches from Harbor Freight.

[brveagle]

Pilot jets are a royal pain.

The last set of carbs i did i had to drill them out.

I would recommend pb blaster over night and then a good fitting screw driver.

[doctorgonzo]

As also noted, VERY careful around the float posts. They will snap off in a second if not very careful.

[tkent02]

If you dip the carbs with the jet installed it may come out after a day or so. Try all the techniques above. Hopefully you won't ruin the jet. If it still will not come out, spray carb cleaner through the jet as well as you can, if it comes out exactly the same places as the other carbs once the clean jets are reinstalled, chances are it may work properly. If not, you can probably ride it while you look around for a replacement carb body.

[chef1366]

Heat and a good fitting screwdriver is key. If you already buggered up the end use an Easy Out with heat.

[Rudeman]

You can also use a good soldering gun to apply heat. Be sure to clean the tip first.

[1_v8_merc]

Thanks guys, alotta good ideas.

Im just going to buy a slightly bigger screw driver and dremel it down, because all the ones I have dont fit perfectly snug.....although I thought it fit well, maybe not quite good enough.

Im just going to keep hitting it with PB Blaster, LW, and carb cleaner.
If it wont budge, im going to torch it alittle bit, or maybe solder gun.


How sensitive is this aluminum to heat? I really dont want to apply too much heat.

BTW: The bike isn't a daily rider or anything, I intended on putting her down for alittle while over the wintertime, then have it ready for summer. I have a mountaineer that i use for daily driving.

[Baatfam]

Im just going to keep hitting it with PB Blaster, LW, and carb cleaner.

I highly recommend this stuff....