Pilot Jet Stripped

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  • LambBrainz
    Forum Newbie
    • Feb 2026
    • 13
    • Near Corning, NY

    #1

    Pilot Jet Stripped

    Took the carbs off the new bike because the previous previous owner (PPO) had pods on it. The carbs would also leak on the side stand; so I wanted to open them up and just clean everything, get some new gaskets, and see if I need to re-jet them back to stock (it has an airbox now).

    To my horror, I found brass shavings on the pilot jet plug as well as the pilot jet completely stripped. I wanted to check with you all and see if my plan is solid or dumb.

    The plan is to use a small drill bit to grab the jet and slowly back it out. Clean everything real good, and replace the jet. I'm really not sure what else could be done aside from getting new carbs, but that seems drastic at this stage. I could also use a screw extractor, maybe (https://www.youtube.com/watch?v=TGYSM3E1K0Y)

    I managed to find some replacement jets that seem to match the manual and what I have in front of me. I'd love some confirmation on that as well (https://www.ebay.com/itm/302809657835)

    image.png

    Last edited by LambBrainz; 03-02-2026, 10:47 PM.
  • Big T
    Forum LongTimer
    Past Site Supporter
    Super Site Supporter
    • Mar 2005
    • 12414
    • West Slope, OR

    #2
    I'd use some penetrating oil, followed by a heat gun
    a proper fitting screwdriver is critical, even if you have to grind one down to fit

    I'd go to Jetsrus.com for the correct jets
    1978 GS 1000 (since new)
    1979 GS 1000 (The Fridge, superbike replica project)
    1978 GS 1000 (parts)
    1981 GS 850 (anyone want a project?)
    1981 GPZ 550 (backroad screamer)
    1970 450 Mk IIID (THUMP!)
    2007 DRz 400S
    1999 ATK 490ES
    1994 DR 350SES

    Comment

    • LambBrainz
      Forum Newbie
      • Feb 2026
      • 13
      • Near Corning, NY

      #3
      Yep, I hate to have inherited this problem, but at least when I'm done I'll know they're good to go.

      jetsrus.com seems perfect; first time hearing about this site and it seems to have everything. Thanks!

      Comment

      • Nessism
        Forum LongTimer
        GSResource Superstar
        Past Site Supporter
        Super Site Supporter
        • Mar 2006
        • 35808
        • Torrance, CA

        #4
        Yes, heat and penetrating oil are good. And drill a small hole and pound in a torx bit that's a little bigger. Those grab nicely.
        Ed

        To measure is to know.

        Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

        Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

        Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

        KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

        Comment

        • dgates1
          Forum Mentor
          Past Site Supporter
          Super Site Supporter
          • Jun 2024
          • 363
          • Arlington, TX

          #5
          If you end up losing all of the purchase you can get on the slot trying with the correct size screwdriver, try a left-handed drill bit after oil and heat. Then a torx if you have to like Ed said.
          - David
          80 GS850GL, 82 GS1100G
          Arlington, TX
          https://visitedstatesmap.com/image/ARMNMTNDSDTXsm.jpg

          Comment

          • LambBrainz
            Forum Newbie
            • Feb 2026
            • 13
            • Near Corning, NY

            #6
            Got it out! Ordered new jets and gaskets

            IMG20260303204153.jpg

            Comment

            • rphillips
              Forum Guru
              Past Site Supporter
              Super Site Supporter
              • Jun 2005
              • 7679
              • Norene TN

              #7
              Congrats, love see'in things that could get pretty drastic taken care of rather easily... Headed in the right direction, keep it up.
              1983 GS1100E, 1983 CB1100F, 1991 GSX1100G, 1996 Kaw. ZL600 Eliminator, 1999 Bandit 1200S, 2005 Bandit 1200S, 2000 Kaw. ZRX 1100

              Comment

              • Rob S.
                Forum Guru
                Past Site Supporter
                • Dec 2013
                • 9475
                • New York City

                #8
                Originally posted by LambBrainz
                The carbs would also leak on the side stand...
                I've always used a brick under the side stand of my 11EZ. In fact, before I replaced the fork springs, I used two bricks!
                It's more esthetically pleasing to me that way (I don’t have a center stand).
                1982 GS1100E V&H "SS" exhaust, APE pods, 1150 oil cooler, 140 speedo, 99.3 rear wheel HP, black engine, '83 red

                2016 XL883L sigpic Two-tone blue and white. Almost 42 hp! Status: destroyed, now owned by the insurance company. The hole in my memory starts an hour before the accident and ends 24 hours after.

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