Completely unable to remove pilot jet

[Mike]

Yeah, but the link you posted was for the entire document. If you don't have a quick internet connection, the time it takes to load the entire document is not worth the wait.

.

Good point. My apologies. In the future, I'll try to just take a picture of my set up, or a screen shot of the relevant part of a large document.

[trippivot]

Whoever got in there last left one of the pilot jets with half of the top missing, making it impossible to remove with a screwdriver. I soaked it with PB Blaster and tried an easy out, and all it did was hollow out the jet. Any suggestions to get it out without destroying the float bowl as it doesn't seem like any place sells just the float bowl?

does the term DENTAL WORK seem unusual ? Not in a situation like you have..

I have sucessfully removed a few mangled pilot jets in my time. I have one and the fragments in a glass jar to show my customers what a worst case senerio can look like.


small porting files, left hand drills, dremel tool, precision drill bits. oh and a truck load of patience.

the easy out removers put pressure on the stuck jet and push it outward only making it stick as hard as you push and twist. #1 way to crack and break the aluminum. You need to remove the brass material from the center out and do not hurt the threads on the inside of the pilot jet channel.

[Matchless]

does the term DENTAL WORK seem unusual ? Not in a situation like you have..

I have sucessfully removed a few mangled pilot jets in my time. I have one and the fragments in a glass jar to show my customers what a worst case senerio can look like.


small porting files, left hand drills, dremel tool, precision drill bits. oh and a truck load of patience.

the easy out removers put pressure on the stuck jet and push it outward only making it stick as hard as you push and twist. #1 way to crack and break the aluminum. You need to remove the brass material from the center out and do not hurt the threads on the inside of the pilot jet channel.

As trippivot said.

I removed two stuck pilots a couple of weeks ago. Drilled the center hole larger in small increments, by using a drill press. It is very important to drill exactly in the center of the stuck jet and exactly perpendicular and not deeper than the end of the jet.

Inspect the hole carefully with a light and magnifying glass after every step. Once you have most of the brass drilled out with a 4mm drill bit, then collapse the remains of the brass inwards from the threads using a small watchmakers screwdriver and a tiny hammer. Then remove the brass carefully.
Try not to damage the threads in the body as they are very soft.
You can clean the threads by carefully and lightly running a tap through it. Blow and clean out properly and use a long screw with the same thread with some anti seize to check the threads.
Having a spare pilot jet in hand to compare depth and thickness helps a lot.

[bluewool]

As trippivot said.

I removed two stuck pilots a couple of weeks ago. Drilled the center hole larger in small increments, by using a drill press. It is very important to drill exactly in the center of the stuck jet and exactly perpendicular and not deeper than the end of the jet.

Inspect the hole carefully with a light and magnifying glass after every step. Once you have most of the brass drilled out with a 4mm drill bit, then collapse the remains of the brass inwards from the threads using a small watchmakers screwdriver and a tiny hammer. Then remove the brass carefully.
Try not to damage the threads in the body as they are very soft.
You can clean the threads by carefully and lightly running a tap through it. Blow and clean out properly and use a long screw with the same thread with some anti seize to check the threads.
Having a spare pilot jet in hand to compare depth and thickness helps a lot.

Holy Crap! that sounds both tedious and stressful.

[Matchless]

Holy Crap! that sounds both tedious and stressful.

You are right on both counts!
About half an hour's careful work and you will be riding again!

[Mike]

Holy Crap! that sounds both tedious and stressful.

Certainly no more tedious and stressful than everything else I've tried.

[Mike]

Can anyone recommed a good site to get the jet from? Z1 and Jets R Us don't list the 17.5# pilot. Might end up ordering from a dealership otherwise.

[cableguy]

Try www.cyclewareables.com

Not speedy, but they (he) seem to be able to get just about anything. Or try www.jetsrus.com

[ddaniels]

Certainly no more tedious and stressful than everything else I've tried.

Please try soaking it with pb blaster, then heat it with a torch, then try a left hand drill bit to back it out before you try chipping it out as described above. Mine backed right out with the left hand drill after the first two steps.

[Testarossa]

Definantly try the left hand drill bit. Best case scenario, it backs the jet out in 10 seconds. Worst case, it becomes a step in your drill out process to chip the jet out of the hole. I have unscrewed a lot of stuff with left hand drills over the years.

[mike_of_bbg]

I've read here that 50/50 Acetone/ATF makes a better penetrating lubricant than just about anything on the market.

[chuck hahn]

Try SUDCO for the jets...they have a free catalog download available and its a HUGE HUGE cartalog.

[karllmt]

What kind of "left hand drill" are you refering? A standard drill in reverse? What kind of "bit?"
Thanks, Karl

[7981GS]

Available everywhere.

http://www.google.com/search?client=safari&rls=en&q=Left-hand+drill+bits&ie=UTF-8&oe=UTF-8

Daniel