On my '09 KLX250, very carefully drilled through the plug that prevents adjustment of the Pilot Jet and then seated it very carefully. Next went to back it out 2 1/2 turns, but small debris from the drilling process gummed up the threads. Now I can't turn it in and I can't back it out. Any thoughts on extracting it - I know the pilot adjustment screw/jet is lost, but I'm hoping there is a way to get it out without wrecking the threads in the carb housing that holds it. Otherwise I'll be shopping for another carb.

 

Can you spray some WD-40 in their to loosen up the debris?

 

****! Use wd-40 like brien said, then when unscrewing (carburetor upside down), tap the outside with the back of a screw driver, that way debri falls down and out

 

oldguido:

That really sux. Can you just leave it where it is?

This is a good "don't do as I do" example.

 

It's not pretty, but I got it out. I'll have to have the housing hole retapped, but I'm fairly sure I can save it. I just kept drilling with larger and larger bits, and prying and poking with a couple difference sized screw drivers until the threaded portion came out. Next coaxed the spring out and finally shook the needle out. Quite sure no harm was done to where the needle seats. Ordered a Kouba adjustable Pilot Screw.

 

If it doesn't work out for you I have the OE carb and a DJ kit I will let you have for $50 plus shipping.

 

I appreciate that offer. We'll see what happens.

 

Well, what happened was I drilled out the pilot jet screw and retapped the hole, but the new pilot jet screw just didn't seem to be seating properly. So I took GBAUTO up on his offer to sell me his '12 carb. It arrived yesterday, was installed and after about a 1/4 second on the button, started right up. This is a great outcome for a bike I picked up with less than 600 miles on it for less than half the price of a new one! Many thanks to Greg for shipping it promptly during the holiday season with a clear description of how he had modified the carb.





It's been a very Merry Christmas - hope yours was too!

 

Glad it all went well. I was hoping that you would get it in time for the holidays.

 

that is awesome.

Glad to hear the story had a happy ending