Broken pilot jet - screwpart still inside - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 15 (permalink) Old 08-11-2017, 10:50 AM Thread Starter
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Broken pilot jet - screwpart still inside

I managed to get to the drain chambers and was able to clean one pilot jet properly. Whilst working on the other one, barely (I think) touching the pilot jet, it came off just like that. That is, it broke off.

The screwpart is still screwed in the carb, only the small 'pipe' part (first part) fell out.

What is wisdom? Take it to the garage and have them drill out the screwpart? Or try to spray carb cleaner and compressed air in the part still inside and hope for the best (idling on one carb :/ )?
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post #2 of 15 (permalink) Old 08-11-2017, 11:45 AM
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definitely won't idle right on only one functional carb, you'll probably have to get an ez-out or left-hand drill bit on it to remove the threaded portion

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post #3 of 15 (permalink) Old 08-11-2017, 11:46 AM
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If the screw portion is still intact, then why can't you simply unscrew it? Maybe a picture would help.


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post #4 of 15 (permalink) Old 08-11-2017, 01:52 PM
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Left hand or reverse drill bit is probably the best bet if you can find one.

May not be able to find an EZ Out that small.

If there's any of the jet protruding beyond the carb body, you might use vise-grips, or cut a slot for a screwdriver. But it sounds like the jet must be cross-threaded, stuck with corrosion, or simply over-tightened. (just snug is all they need to be)

Otherwise, the whole jet will need to be drilled out without damaging the threads in the carb body. Might be a job for the machine shop.

Cleaning jets while they're still in the carb will just push dirt deeper into the carb passages.

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post #5 of 15 (permalink) Old 08-12-2017, 04:03 AM Thread Starter
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Thanks...

Yes, the ez-out might be hard to find that small, though there are some manual removal drills that may be smaller than the standard ones. Otherwise careful drilling might do the trick.

I've ordered a new pilot jet in the meantime. Somewhat confusing to know which one to order for my 1992. I've ordered 92064-1123 (#35), but there's also the option to select 92064-1118 for this model. Hopefully they both fit
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post #6 of 15 (permalink) Old 08-12-2017, 05:43 PM
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I thought the stock pilots were #38's....sorry I don't have the part number.

+1 on drilling the part out. Be real careful.... If you posted a photo it would help.

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post #7 of 15 (permalink) Old 08-12-2017, 08:27 PM
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I thought the stock pilots were #38's....sorry I don't have the part number.

+1 on drilling the part out. Be real careful.... If you posted a photo it would help.
When I saw the #35, I thought it must be a number from a parts fiche. Then I just now decided to google those numbers. #35 and #38 are the actual jet sizes.

92064-1118 is shown as a #38, the correct stock pilot jet.

92064-1123 is shown as a #35, a much smaller pilot jet. It's going to be really lean and probably won't run right, or run hot.

Need to change that order maverikster.

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post #8 of 15 (permalink) Old 08-13-2017, 02:02 AM Thread Starter
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oh man... thanks for the heads up! I'll change the order right away.

When I get the chance I'll upload a pic of the current situation
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post #9 of 15 (permalink) Old 08-13-2017, 04:33 AM Thread Starter
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Here's a vague pic of the broken jet. You can see it's broken off at surface level. Wish I could try to take it out, but at the moment I've given up on removing the carbs completely from the bike. I can't seem to get the airducts out of the surge tank (pulled the surge tank as high as possible with strapbands; afraid any further and it will snap) and without it, there's not enough room to take the carbs out :/
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post #10 of 15 (permalink) Old 08-13-2017, 09:48 AM
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I've hauled pretty far up on mine several times, and it's no worse for the wear. For the ducts, you should be able to just smush the side that goes into the surge tank with your hands and pull them out that way. They should be soft rubber, so if they get bent out of shape a little, it should be ok. If they get deformed and don't restore themselves, they should probably be replaced anyway. Getting those air ducts out of the way and being pretty aggressive with lifting the surge tank should give you room enough to get the carbs out. I found getting them as high as possible between the cylinders was helpful, then being slow and methodical. Move them until something hits, then look at what hit, move to free whatever hit, continue until you slowly work them out. Be careful not to use brute force because aluminum is soft.
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