stripped pilot jets

[oldbiker648]

Three of 4 of my pilot jets are stripped. The PO must have tried to remove witha 50 cent screwdriverthat didn'f fit the slots and without using pentrating oil and. Short of drilling them out, can I hose them down well with carb cleaner and hit them with compressed air to make sure the small holes are open? The one I was able to remove didn't look too bad. I know this is a band-aid, but I'm a little nervous trying to drill them out without a drill press.

[Pat Kelly]

I had a stripped one that wouldn't get fuel right. The bike ran on 3 cyl until 4,000 RPM when the carbs transition to main jets. Then the dead cylinder kick-ed in and YEEEE-HAWWWW!!

I removed mine with a tiny "EZ out" (a delicate 1/8" thing). As a test I moved it to another cyl and the problem moved with it.

[oldbiker648]

Thanks Pat,
I'd hate to totally reassemble the carbs and have a problem like you mentioned. I suppose NAPA would have the small EZ-Out. They're made of carbide aren't they? Probably snap if not kept perfectly straight. You would have thought the PO would have quit after stripping out the first jet, but nooo, he was very persistent.

[skids]

If you go the EZ-out method, drill the hole as big a diameter as you dare and make sure you don't go too deep! I have heard (and have not done it) that reverse-twist drill bits can actually free-up the pilot jet and turn it out.

Originally posted by oldbiker648
Thanks Pat,
I'd hate to totally reassemble the carbs and have a problem like you mentioned. I suppose NAPA would have the small EZ-Out. They're made of carbide aren't they? Probably snap if not kept perfectly straight. You would have thought the PO would have quit after stripping out the first jet, but nooo, he was very persistent.

[oldbiker648]

Skids,
I bought a set of EZ- outs today at the auto parts place. The smallest is 7/64" , which should work OK. I'll hose the jets down with penetrating oil before I do any drilling. That's a good idea about the reverse twist drill bit. I'll shake down my fastener vendor for a couple. No rush to do the work until I get replacement pilot jets. Always something, right?

[ccogswel]

I had three out of four striped on mine as well. I took the smallest EZ- out I had and I just put it in the pilot and started it with my fingers first. Mine came out just fine except I had to replace them. I could have reused them but I didn't want the headaches.

Just one more thought I remembered. If you do reuse them, you really need to check to make sure you clean them as with the PO tring to get them out as well with you, there may be some small pieces of brass from the screw driver as they were tring to be removed. That was another reason why I just went and got some new ones. Hope my two cents worth helps! As it really is not worth two cents. LOL

"Sorry for any typo's as I can't spell"

Chris

[oldbiker648]

Chris- Just checked the EZ-out set I bought and the smallest one is too big to fit into the top of the jet without drilling. I'm surprised that these things don't have very sharp edges. There was another set that were square shaped with very sharp edges and I think I'll buy them and see if they might work without drilling. I plan on replacing the jets anyway. Will buy a new set of 4 and keep the "Lone Ranger" as a spare.

[noeleo]

The square type extractors work just fine without drilling. The set I bought was from a company called Vermont-American. The smallest size inserted just fine, and removed the pilot without further damage. Cleaned up just fine, and am running it now. Ordered some new ones from Bike Bandit, but were backordered. Maybe try Mike's XS...

My $.02

[ccogswel]

John,

I checked my set of EZ outs. The smallest one I have is 5/64. It looks like a reverse wood screw. I had bought this set from a Big A auto parts store back in 1988 or 89 when I lived in Colorado. I don't even know if they make these type any more. The only ones I see any more are the square ones. I know it can be done as it worked for me.

Good Luck!!

Chris

[oldbiker648]

Chris,
My smallest is 7/64". I'm going to swap this set out for the square ones. The edges of the flutes seem too smooth to get a good grip unless you really gave the tool a solid whack with a hammer, which I'd rather not do to a carb. I'll let you know how the square ones work out.
John

[81XS11LadyRider]

I had a similar problem, so I bought an EX-1 spiral screw extractor (which says use with 5/64" drill bit) from the local chain hardware store to remove the pilot jets. It worked fine for me and I didn't have to do any drilling!

[oldbiker648]

Yours is the second reply stating that no drilling was required to remove the pilot jets. I bought the set of "square" screw removers this weekend and the smallest one calls for a 1/8" drill bit (8/64") and is too big to fit the jet with no drilling. Sounds like I need to make the trip to the hardware store instead of the auto parts.
By the way, I have to hand it to you for choosing an XS-11 for a first bike. The margin of error is pretty thin with these heavy powerful antiques, but the satisfaction of owning one and keeping it running has a value of its own.

[ccogswel]

John, if you have no luck at the hardware store I thought maybe you could track down a MAC or Snap On tool truck. They should have something to help. If you don't have any luck finding something and you want I can send you my set of EZ-Outs so you can fix it and then send them back when your done. Either way I hope you have good luck. By the way, what year carbs are you working on?

Chris

[oldbiker648]

Chris,
Thanks for the kind offer to lend me your tools. If I can't find what I need by the end of the week I may take you up on it. The carbs are off my '81 H. I ordered replacement pilot jets from Mike's XS last night, $6/pair. I was also stymied on the master cylinder from my XS650 and ordered their 90 degree snap ring tool specifically for rebuilding MC's. I hope to get at least one of the bikes back together this weekend.

[oldbiker648]

Thanks to those of you who suggested the small (5/32") EZ out to remove the stripped out pilot jets. Yanked all 3 in about 2 minutes with no drilling. The EZ out was $1.65 at the local hardware and I should have 4 new jets from Mike's by Friday. I love it when a plan comes together.