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Discussion Starter #1
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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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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If the screw portion is still intact, then why can't you simply unscrew it? Maybe a picture would help.
 

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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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Discussion Starter #5
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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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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Discussion Starter #8
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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Discussion Starter #9
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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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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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.
 

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Discussion Starter #12
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 :)
 

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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.
 

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Discussion Starter #15
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 :)
 
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