Ok, gotta problem. I'm trying to re-jet my carbs, but one of my pilot jets won't budge. I put the biggest flat-blade screwdriver that fits into the hole, turned, and the slots sheared right off.

any tips? I got the other one out no problems, looking at it, i wonder if an extractor will just make things worse.

can it be drilled out, or it that gonna just ruin the carb? or should I tap an extractor in there and hope like heck it won't just tear it up worse?

I've had luck with left hand drill bits like these.

http://www.mytoolstore.com/hanson/hanson.html

Usually, as you are drilling, the screw will break free and back out. I've never had to try it in a carb though, just other places.

You might want to soak it with some "weasel piss" before hand

please excuse the mild panic attach i just had...  

I tapped a small 'jewelers' phillips head into the jet, put a pair of pliers on it, and cracked it loose.... whew!!

Oh good ... but ditto on the left handed drill  ...
Cool.
Srinath.

Been noticing that it has been happening alot, this shearing of pilot screws. Brass right? Soft metal. What's causing them to get stuck like that? Dried gas? Deposits?

Should we issue a warning about these since we, as GS owners, are typically changing these jets to cure the known carburetion problems that most U.S. GS's have?

A mere suggestion to use Liquid Wrench, WD40 or whatever to help loosen these parts before requiring a drill?

Quote from: callmelennyYou might want to soak it with some "weasel piss" before hand

hey!  carefull....  :mrgreen:

Quote from: scratchBeen noticing that it has been happening alot, this shearing of pilot screws. Brass right? Soft metal. What's causing them to get stuck like that? Dried gas? Deposits?

Should we issue a warning about these since we, as GS owners, are typically changing these jets to cure the known carburetion problems that most U.S. GS's have?

A mere suggestion to use Liquid Wrench, WD40 or whatever to help loosen these parts before requiring a drill?

May be a good idea to put a warning. I sheared the slots off the pilot jets too.  It's really weak material, it kind of crumbles. Luckily my GS is fitted with #40 pilots as a standard, so I chose to let them sit that way. (they were plugged, but managed to clean it with some solvent. )

I blame cheap screwdrivers.  I thought mine were a lost cause but then  I bought an ten dollar screwdriver that was the right size, applied a lot of downward force, and it eventually twisted out.  Nothing will tear up a nut, bolt, screw worse then a cheap tool or one that is the wrong size.  No wonder mechanics pay tens of thousands for Snap-on tools.

I actually blame over tightening ... Use finger tip pressure only ... its not a load item .. you aren't attepting to pull a trailer with your pilot jet ...  Most of the trouble I have had is with carbs that look like they've been apart  ... Mechanics overtorqueing them ... its a tiny brass object in a cast sheite aluminum housing ... either way you look at it ... like American Idol ... there are no winners here ... losers only ...  :x  :x  :x
Yea finger tip only when tightening ... no gripping it like a baseball bat and cranking it like a lug nut on a semi truck ... And Yea right tool .. while doesn't have to be $10 ... helps ... I prefer the large rubber handle sears issue ones to take off and use just fingertip to put the new ones back in ... BTW take it off and its history ... new only back in ... whihc is really why  dont want to drill out the few dozen 37.5 I have lying about and start putting them in carbs ...
Cool.
Srinath.