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Messed Up Pilot Jets Stuck - Anyone Good at RemovingThem?

Mr.humbucker

Mr.humbucker

Forum Mentor
Past Site Supporter
I have a set of GS650G 1982 carbs that are in great shape but the previous owner messed up the slots of the pilots jets and I can not get them out. I have searched out the different remedies and tried a few on other carbs that have the same problem with no success. I am hoping their may be a carb guru out there that I could send them to and have them get them out successfully. It has to be cheaper than starting over with another set off eBay that may have a similar problem.

if you can help, shoot me a line!
 
There's a couple more things you can try:

1. cut the slot deeper in the jet, then
2. Heat them up. A halogen lamp is useful if you have one. Point it up and lay the carb body on top for 15-20 minutes. Using oven mitts, try to turn the jet out
3. a long session in carb dip

Be sure to use a screwdriver than matches the slot. The problem is that the dissimilar metals have stuck together
 
Use a heat gun with a very small nozzle attachment (about 10 mm diameter) to heat just the area of the body around the pilot jet.

Using a small hammer, tap the longest flat-tip screwdriver you have that fits properly into the pilot jet, with a few smart taps (an electrician's screwdriver with the parallel flat tip fits a lot better than the mechanics screwdriver with the profile tapering towards the tip). I have found that a screwdriver at least 12 inches long works best.

Note that you cannot cut a slot into the jet because it sits too deep down into the carb body.

Luckily for me the above process has always worked, and I have never had to resort to left-hand drills or similar drastic methods!
 
I removed a stuck, slot-stripped pilot jet by lightly tapping in a small phillips head jewellery screwdriver into the jet orifice of the jet with a small hammer. I then used a small pair of vice grips to rotate the jet out. Sort of a home made ezi-out. No damage was done to the carb body. I was very careful
 
Thanks to those that have offered some solutions here. I have reached out to David who fortunately lives up the road in Langely BC to take him up on his offer. I've tried the heat and tapping a variety of screw drivers into what is left in the slot to no avail. There's no way, that I can see, to cut any slot into the head of the pilot jet as it is too far down in the body. Wish me luck, hopefully David will be able to help me out. Regardless I'll be nominating him for GS Member of the month for his kind offer to help!

Hmmm, maybe I'll start new thread entitled "GS Member of the Month" where we can recognize those in the group that go the extra mile (or Km in Canada) to help out others!
 
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