just purchased an 06 KLX250s with 331 kit and a TM36 carb installed. Starts up and runs just fine while one choke, but won't idle with choke out. First step, I took a look at the pilot screw. Low and behold, out came the screw.. but with no needle. Needle is stuck in the carb. I tried using a sewing needle to push it out, no good.

Anyone have an idea how to get this out of here before I drop some cash on a new carb?

 

Did the washer, spring and o-ring come out?

unscrew the Pilot Air Jet (PAJ) in the carb bellmouth. Shoot carb cleaner down this hole and see if the pilot circuit is clear or dislodges the needle. May have to use compressed air nozzle if really stuck.

 

Man, those are tough deals when that needle tip breaks off in the passage. Soft brass smashed into the cast pot metal of a carb is often the kiss of death for the carb. On the rare success story I've heard of, one involved stripping the carb down to basically a bare body and boiling the body for a few minutes. Then immediately and while the carb cools, use high pressure compressed air in the passage to try to dislodge the needle tip. Apparently the two dissimilar metals allow different expansion rates and the tip might dislodge. The brass and pot metal are so dissimilar that when that tip breaks off and really smashes tightly in the passage, it's nearly impossible to get out without damaging the passage. Still, people have successfully gotten it out occasionally.

 

no good. I tried but it looks like it was stuck in there good for some time. Screw was really tight as well. New carb on its way in the mail.

I don't consider it a major loss as I got the bike for an amazing price. I'm still not into it far enough that I feel I've spent what it's worth. I could have gotten a new tank for the cost of that carb though, such is life.

 

Good attitude, be glad it wasn't a $500 FCR. Were that my case, I'd be seriously bummed and walking.