Can't Remove Pilot Jet, Now What?

[Anonymous]

I'm working on a set of GS1100GLZ carbs. I have the pilot jets out of three of the carbs. On carb #3, the jet is stuck. When I say stuck I mean really stuck. With the carb clamped in a vise and me pushing down with most of my weight on the screw, the tip of the screwdriver broke. This is after spraying Aero-Kroil into the hole and letting it soak for more than a day. I haven't been able to move the screw at all in either direction.

At this point, I have a few ideas: Take it to my local machine shop where they've been pretty good at removing broken bolts, try heating with a butane torch, or try drilling out the screw.

If I heat it, can the carb body take the heat? Should I try to get as much heat on the screw as possible?

If I try to drill it out, is the screw made of a material that can be drilled? It looks like it might be made of a hard-to-driill metal.

Any suggestions or other ideas would definitely be apprediated.

[Pete's GS]

Oh, the dreaded frozen GS pilot screws. Robert Riles at motorcyclecarbs.com can remove them with an Eazy-Out. Or try a machine shop you have confidence in. The area for error is pretty small if you're going to have someone drill them out though. BTW, the screws were frozen by Mikuni, and some or none or all can be so set. Some people think washing a bike with laundry detergent and its getting into the threads is what freezes them

[KennyJ]

I heat the body with a propane torch...and have done many this way. Just heat the tube until you can't touch it, then try again. It should back out. I have never seen cast aluminum melt with a propane torch, so heat away!

Kenny

[Anonymous]

Got it out! The propane torch did the trick. Thanks KennyJ!

It was still tight and creaked all the way out, but it did come out. Once it was out, I could see that there was corrosion--the spring was rusted.

These carbs are off a bike that sat under a tarp in Seattle for 10 years. Needless to say, they were pretty cruddy. I'm surprised that only one of the jets gave me trouble. As it is, with the help of a can of Berryman's, they're cleaning up well.