Removing stuck carb Jets

[jetmechmarty]

Mine came out with a left hand drill bit. Turning the chuck slowly by hand was enough to grab it and get it out.

[copeland3300]

I believe that I still have the slots for the screw driver. I was going to try this last night, but I didn't have time.

I'm thinking that rather than the propane torch, I could start with a heat gun. I also have to grind a screwdriver tip to fit into the slot.

I had an interesting idea this morning which was to get the area nice and hot with the torch, and then turn a can of air duster over and spray the jet. I decided this was a bad idea because I don't want to crack my carb housing.

Aluminum (I think that's what our carbs are made of) apparently has a higher coefficient of thermal expansion than brass does, so at least it jet won't be embedding itself further and further into the threads as I warm it.

[bikerphil]

I also have to grind a screwdriver tip to fit into the slot.

Yes, this will absolutely increase your chances of it coming out, I have a dedicated screwdriver that I have ground down to fit the pilot jet tower perfectly. It has never failed me yet. <knock>

[tarzan]

Yes, this will absolutely increase your chances of it coming out, I have a dedicated screwdriver that I have ground down to fit the pilot jet tower perfectly. It has never failed me yet. <knock>

I ground one too.A few years back.Works great.

[copeland3300]

SO! I had a screw driver that was about the right size for the jet. It however, didn't do the trick on any of them. I used my heat gun on the tower for a few minutes to get it nice and hot, let it cool for a minute or two, sprayed in some PB Blaster, then hammered in the screw driver a bit and tried it.

It didn't move.

I ended up tearing up the majority of the base of the jet. The threads are still there, and the parts of the jet above the threads are also still there. I tried hammering in several different sizes of EZ outs (which were apparently soft enough to bend, not break) and nothing.

Next I'll try re-soaking in PB blaster, a butane flame and left handed drill bits.

[jetmechmarty]

A careful slow turn with the left hand bit should get it. Try turned the chuck by hand first. I watched somebody else do it this way most recently.

[crazy steve]

One problem with ez-outs is they expand the part being removed. Not what you want in this case....

[bikerphil]

I've had luck hammering an allen wrench into the jet and turning it out. Could probably also use a torx. Find one just slightly larger than the hole in the jet. You may have to drill a new hole to accept the wrench. At least you know the allen wrench won't snap off and be stuck in there. JAT

[tarzan]

You will now probably have to drill it out. Just start with a real small drill first.Then go a little bigger, a size at a time, until you see a thin aluminum spiral through the hole. Be careful not to go oversize. Once you see aluminum you should be able to peel the thread out like a brass spring.I use a pick and just dig out the start of the spiral and then use hemostats or needle nose pliers to grab it and pull it out.

[copeland3300]

Unfortunately, I think you're right, tarzan. I got one more of the jets out, but I was SOL on the other two. No amount of heat, lube and removal tools seemed to work. The brass would always fail before the threads let go.

Oh well. These things happen, right?!

[Bonz]

You guys like talking about the same stuff, different day, eh? Yeah, me too.

Here's the thread I started not long ago, http://www.xs11.com/forum/showthread.php?t=38681

Maybe you can pick up some info here that hasn't been re-stated. It is even still on the first page of discussion, so you can find it easier. Must be winter, as no one says "use the search function" due to not being out riding, rather we are all sitting around our computers!

However, as to not be a wet noodle, I won't say anything about the search function in this thread, carry on gents!

[copeland3300]

I saw yours and mentioned it in the first post. Mainly I was just trying to see about compiling a list of all the ways to remove a stuck jet. Then it just turned into a thread about my specific issue, lol. Oh well.

[Bonz]

Alrighty then... What an a-hole I must seem to you right about now... I know I feel like one... Better open my own darn eyes and read, eh?

I'm really a pretty likeable guy.... um.... right guys?

[copeland3300]

Hehe, no worries, I don't think anyone's really worried about it. I haven't gotten the sense that this is a place where people do a lot of epeen related arguing, rather people are just trying to help everyone out. It's a nice change of pace from what I'm used to on a lot of tech forums.

Also, one other question. I'm using pods and the stock exhaust. I'm thinking of going with 45 pilots and 142.5 or 145 mains. That seems to be the consensus.

Sound good?

[Bonz]

The bike in question is an 80G correct? My 2001 ZRX 1200 is running pods with a full aftermarket system, and stock was 92.5, I run 125 mains at my high eleveation, so that is a 30 pt gain, per se. Going to 142.5 or 145 mains would be a similar equivalent gain, so to my logic seems pretty good.

The stock XS exhaust is deemed pretty much as good as it gets for power making and flow, so wondering how much the pods/jets are gonna gain in hp over stock?

Any definitive gain that can be shown from others that have gone before, so to speak, in the form of dyno charts with your combination?

FWIW, My ZRX 1200 went from 112 hp, 80/ft/lb stock to 130 hp, 85 ft/lbs with the above pods, jets, full system.