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Thread: Broken pilot jet - screwpart still inside Reply to Thread
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  Topic Review (Newest First)
08-14-2017 10:55 AM
maverikster Yes, that must be it; those ducts aren't flexible at all... Might have to replace them, or go for the earshave indeed (probably go for replacement first
08-14-2017 09:59 AM
Spockster It's not good to clean the jet while it's still in the carb, you'll be pushing dirt deeper into the passages.

The air mixture screw can't compensate for a clogged pilot jet.

Very likely at least some of the emulsion holes in the pilot will be plugged.

Should be able to grab the duct, squeeze it together and pull down from the airbox. Though it does sound like yours may have hardened with age.

It's a good candidate for the earshave, maybe.
08-14-2017 08:53 AM
Knifemaker I believe the pilot jet also has holes along its walls. You can't clean those without removing it from the carb. Not saying yours are blocked up, you might get it cleared running a wire through it... but then maybe not.
08-14-2017 05:01 AM
maverikster After the encouraging words from both of you, I did give it another shot... But just couldn't do it (tried screwdriver as well, but afraid I'll puncture parts of the rubber). The front boot would probably come off at some point, but the rear one is just impossible (for me to put enough force on from the available angles.

So, it'll go to the mechanic.

I might try to clean the broken jet from the outside (carb cleaner, guitar e-string, compressed air), assuming the actual length of the jet (as it's broken at drain-chamber surface level) can be compensated for by messing around with the airscrew (and assuming I can get some of the dirt out without removing the pilot jet). But, as assumption is the mother of all ****-ups, not sure whether this has any chance of success
08-13-2017 09:58 AM
Spockster The ducts are pretty flexible, just squeeze inward until there's a gap, put a screwdriver in the gap and pry down while squeezing in another spot.

The airbox will flex a little too..

If you could get the carbs removed, I would start soaking that jet with penetrating oil.

One good thing, the jet is brass and easy to drill. After you get it drilled beyond the threads, try reversing the drill and see if it happens to spin out, sometimes the threads relax when the hole is drilled, and the heat from drilling helps too. The threads are only at the top 1/4" of what is showing, check the jet pics where you ordered.
08-13-2017 09:48 AM
wmdaricthompson 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.
08-13-2017 04:33 AM
maverikster 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 :/
08-13-2017 02:02 AM
maverikster 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
08-12-2017 08:27 PM
Originally Posted by Knifemaker View Post
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.
08-12-2017 05:43 PM
Knifemaker 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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