stuck pilot jets

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Hansmann
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stuck pilot jets

#1

Post by Hansmann »

Hello
I have laid my hands of a set of gl 1100 carburetors. I am not sure about the year! They are in a pretty miserable stage and the two of them are a bit oxidized as if they have been stored in a humid place for an extended period of time. Yet nothing is broken. I have taken them almost fully apart and if I have them cleaned, I am sure they can become full functional. There are a loads of internet recourses on how to accomplish such a job and I very tempted to take the challenge myself. I have a few issues that kind of stops any further progress, and any suggestion would be very helpful.

Pilot jets are stuck on two of them. I haven’t ruined the screws (yet). I have soaked them in W40 and what not, but they seem still stubborn. I am a bit hesitant to use heat since aluminum lead heat very fast and there might be a chance that I melt the o-ring inside?

Needle jet removal: I am a bit inclined to try to remove the idle jet for a through clan. However, I am not sure whether these are of the removable type! Can the year be determined by the number typed on the carburetors thus identifying the year?

Kind Regards,
Hans
past:
Yamaha XS 650 1975
Kawasaki Z650 SR 1983
current:
Honda gl 1100 1982
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gltriker
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Re: stuck pilot jets

#2

Post by gltriker »

Next post down for Mike Nixon's information
Last edited by gltriker on Sun Jan 22, 2023 10:21 am, edited 1 time in total.
Cliff (74yrs ;) )

Keep your eyes and ears open and you'll learn something new, everyday. tumb2

New users please visit our "Shop Talk" for common tips and help: <---jdvorchak
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^^^^^^^click up here^^^^^ :oldies

RE: a thorough fuel tank cleaning
"And your carbs will thank you. They no longer live down stream from a sewage plant." -gregforesi tumb2
"Can't see the paint when your looking thru the handlebars..........." -Oldewing ;)
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Cliff

'75 GL1000 home built trike; http://www.ngwclub.com/forum/viewtopic.php?f=30&t=39996
October,2017 BOTM :shock: https://nakedgoldwingsclub.com/forum/page/Welcome

previous rides:
1953 H-D Servi-car, naked, 1969-1978 (serial#53G1559 committed to memory!)
1980 CB900 Custom (triked) 1997-2003 .... R.I.P.
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gltriker
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Re: stuck pilot jets

#3

Post by gltriker »

This Topic link may be very helpful

viewtopic.php?t=67428
Cliff (74yrs ;) )

Keep your eyes and ears open and you'll learn something new, everyday. tumb2

New users please visit our "Shop Talk" for common tips and help: <---jdvorchak
http://www.ngwclub.com/forum/page/ST
^^^^^^^click up here^^^^^ :oldies

RE: a thorough fuel tank cleaning
"And your carbs will thank you. They no longer live down stream from a sewage plant." -gregforesi tumb2
"Can't see the paint when your looking thru the handlebars..........." -Oldewing ;)
"I'd rather Ride than Shine" -RAT tumb2 Me Too!!

Cliff

'75 GL1000 home built trike; http://www.ngwclub.com/forum/viewtopic.php?f=30&t=39996
October,2017 BOTM :shock: https://nakedgoldwingsclub.com/forum/page/Welcome

previous rides:
1953 H-D Servi-car, naked, 1969-1978 (serial#53G1559 committed to memory!)
1980 CB900 Custom (triked) 1997-2003 .... R.I.P.
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Sidecar Bob
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Re: stuck pilot jets

#4

Post by Sidecar Bob »

If your jets are the screw in type you might want to try using a real penetrant instead of WD40.
The name of WD40 means Water Displacer, 40th formula tried. It does not penetrate into threads &c very well so it won't loosen things that are stuck very hard.
Real penetrants like PB Blaster, Liquid Wrench, Kroil or even a 50:50 mix of acetone and ATF will loosen things much better.
Mr. Honda ('83 GL1100/Dnepr) summer How a motorcycle evolves thread
The Famous Eccles ('84 CX650EI/VeloUral) winter Never Ending Build (CX500forum)
Click: Colour schematics for all GL1000 & GL1100 and GL1200 standard models plus instructions on how to download the full size version
"A guy with two sidecars can't be all bad." - Cookie
Another guy with two sidecars..... Hmmmm... must be something to that....
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Hansmann
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Re: stuck pilot jets

#5

Post by Hansmann »

Thanks a lot for your advice! It turned out that the jet was the screw in type and I just got it out quick and easy. I´ve included a few pictures of one of the instruments that is in the worst shape. I am still struggling with the idle jets that are badly stuck! Do you think this is a hopeless project? Once I’ve got the idle jets out, I will have them water blasted by a guy in the neighborhood that runs a small shop that do these kinds of things. Then put everything together and polish the top covers and manifolds 😊 I am out of the town the next couple of weeks, but I will keep you posted when I am back.
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past:
Yamaha XS 650 1975
Kawasaki Z650 SR 1983
current:
Honda gl 1100 1982
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pidjones
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Re: stuck pilot jets

#6

Post by pidjones »

I think that you will also have to remove the aluminum "puck" and clean the ports under it.
"Love 'em all.... let God sort 'em out!"
Ex 2006 GL1800 - the Black Pearl SOLD! to make room for:
2021 Can-Am Spyder RT Limited Dark Chalk Metallic
1975 Red GL1000 project - ex Pistol Pete project
1972 Triumph T150V Trident rescue - finished and FOR SALE!
1976 Yamaha RD400c
1978 GL1000 with '75 engine - the Hunley
Ex 1978 GL1000
Ex 1979 GL1000
Ex '79 CB750F rat bike
Ex '86 SEi
Ex '77 GL1000
Ex '76 RD400
Ex '72 Penton 125 set up for flat track
Ex '73 RD250
Ex '68 TR6C - chopped
Shadowjack
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Re: stuck pilot jets

#7

Post by Shadowjack »

Putting the bodies in boiling water for a bit will soften the varnish. May make the jets easier to remove.
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Hansmann
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Re: stuck pilot jets

#8

Post by Hansmann »

@pijones; Is the aluminum puck the little gismo next to the idle jet and how do I loosen that??
@Shadowjack; great idea. Would it make sense with a few spoons of vinegar to lower the Ph
past:
Yamaha XS 650 1975
Kawasaki Z650 SR 1983
current:
Honda gl 1100 1982
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Sidecar Bob
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Re: stuck pilot jets

#9

Post by Sidecar Bob »

Randakk says
Circular aluminum “puck.” This is about the size of a large aspirin tablet and is located beneath the bowl gasket in the main carb body. It’s necessary to cover the access point used in the manufacturing process to create by-pass transfer ports for the idle circuit. It’s mandatory that you remove these to clean the hidden passages. Usually, compressed air applied through the idle mixture adjustment screw hole will pop them out (and cause them to fly across the room!). Sometimes, they are really stuck and solvents are necessary (apply through the idle mixture adjustment screw hole). Occasionally, heat is necessary to free them. Sometimes they won’t budge and it’s necessary to remove them with brute force. In these cases, I “install” a sheet metal screw into the puck to provide the purchase necessary to remove. Unfortunately, the pucks aren’t available from Honda, so if you need replacements, you will need access to a stash of salvage parts or buy Randakk’s exclusive puck reproductions: Click here
Mr. Honda ('83 GL1100/Dnepr) summer How a motorcycle evolves thread
The Famous Eccles ('84 CX650EI/VeloUral) winter Never Ending Build (CX500forum)
Click: Colour schematics for all GL1000 & GL1100 and GL1200 standard models plus instructions on how to download the full size version
"A guy with two sidecars can't be all bad." - Cookie
Another guy with two sidecars..... Hmmmm... must be something to that....
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Dr. Frankenstein
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Re: stuck pilot jets

#10

Post by Dr. Frankenstein »

Or instead of paying $15.36 + shipping for four little aluminum plugs, you can get four 12-inch aluminum 5/16" round rods from eBay for $14 and find somebody with a lathe to cut you as many as you want. Cut to size, the plugs are 5mm tall and they fit perfectly. I've got these in my '78.

https://www.ebay.com/itm/361113801861?h ... R8zs94y8YQ
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pidjones
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Re: stuck pilot jets

#11

Post by pidjones »

Or, just drill shallow blind hole in it, tap for a screw to pull it with, and reuse.
"Love 'em all.... let God sort 'em out!"
Ex 2006 GL1800 - the Black Pearl SOLD! to make room for:
2021 Can-Am Spyder RT Limited Dark Chalk Metallic
1975 Red GL1000 project - ex Pistol Pete project
1972 Triumph T150V Trident rescue - finished and FOR SALE!
1976 Yamaha RD400c
1978 GL1000 with '75 engine - the Hunley
Ex 1978 GL1000
Ex 1979 GL1000
Ex '79 CB750F rat bike
Ex '86 SEi
Ex '77 GL1000
Ex '76 RD400
Ex '72 Penton 125 set up for flat track
Ex '73 RD250
Ex '68 TR6C - chopped
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Dr. Frankenstein
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Re: stuck pilot jets

#12

Post by Dr. Frankenstein »

That too; it's just a plug, after all. I tried that screw method with mine though and it mangled 'em pretty good, they just did not want to come out of their hole so I went looking for another solution.
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Re: stuck pilot jets

#13

Post by Shadowjack »

"Find somebody with a lathe", hah! 😏 Not so easy in some places, or if you did, it would be a commercial shop, which would charge you more than Randakk. BTW, those pucks sometimes just fall out, although if everything is frozen up, that won't be likely.
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Dr. Frankenstein
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Re: stuck pilot jets

#14

Post by Dr. Frankenstein »

Okay - so pay the man. I was just relaying what worked for me. True, I didn't have the means to cut the aluminum cleanly, so I contacted a local machine shop and they asked for $20 I think it was, since it was such a straightforward cut, so I think I spent $34 overall for the rods and the cutting, and had to wait a bit until they got to it, but I was rebuilding the bike anyway. But it gave me 15, minus the four I put into the '78, leaving 11 left over, more than I'll ever need.

I tried to cut them myself, but it didn't look so good - mine's on the left (obviously), with the OEM on the right. It's tightly machined, so I gave up and had somebody cut me a bunch:
DSCN2012.JPG
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So, $34 divided by 15 comes out to about $2.26 apiece, times four is $9.04, six dollars below what Randakk is charging for four of them ($15.36 plus shipping). And I still have eleven extras. Sure, it's quicker and easier to buy them - but now I know I can have them made. Whatever; I think it was worth it.

Plus, I established a relationship with the machine shop, who thought the project was interesting and was kind enough to laser-cut me out some front pad springs for both the '75 GL1000 and the '78 GL1000, which takes two different shapes and are pretty much unobtainable. That was a bit pricier - I had to buy the sheet of .02 spring steel and they charged me $50 to cut it, and I had to bend them into the correct shape - but now I have 35 of them. Here's the OEM broken one on the left; the other OEM one on the right next to it; and the one I had cut and had to bend to fit next to that, with the blank cutout underneath:
DSCN1908.JPG
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OEM's on the left, mine's on the right:
DSCN1916.JPG
DSCN1916.JPG (122.27 KiB) Viewed 356 times
Here's how the ones I made fit:
DSCN1918.JPG
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The ones for the '78 were a bit trickier- they have that tongue in the middle - but here's one I also made -
DSCN2051.JPG
DSCN2051.JPG (94.76 KiB) Viewed 356 times
Yeah man - you gotta love a good machine shop.
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Sidecar Bob
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Re: stuck pilot jets

#15

Post by Sidecar Bob »

On the other hand, Randakk's sponsors this forum AND he made them available to people who don't have access to a machine shop.
Mr. Honda ('83 GL1100/Dnepr) summer How a motorcycle evolves thread
The Famous Eccles ('84 CX650EI/VeloUral) winter Never Ending Build (CX500forum)
Click: Colour schematics for all GL1000 & GL1100 and GL1200 standard models plus instructions on how to download the full size version
"A guy with two sidecars can't be all bad." - Cookie
Another guy with two sidecars..... Hmmmm... must be something to that....
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