Hi Guys, found this website while researching this frustrating issue with a newly acquired FJ1100. Took the carbs off to rebuild them, and only 1 idle jet was able to be removed. The other 3, the flathead slots are all sheared off and I have no way to grab them.
As you all probably are well aware, these tiny jets are down inside a tube. Is there a trick or tool you guys have to get these things out? Do they make extractor bits this small? or? Any advice is appreciated.
There's a number of YouTube videos for removing jets that are like yours. I had success once drilling one out to a hole size slightly less than that of a spline key. I drove the spline key into the hole with a small hammer. I heated the carb body up good with a heat gun, particularly in the area of the jet. Gave the spline key a twist, and the broken jet unscrewed out of the carb body.
You might want to entertain just getting another set of carbs (eBay), that are in usable condition, going through them, throwing them on your bike and enjoying the ride. Summer and the riding season are in full-swing.
If you're not versed on what you're attempting, you may be in for grief, that's why I suggest a different set from eBay or somewhere.
If you want to continue down the path that you're currently on, perhaps I can help you with some parts. I have some good carb bodies and such. PM me with your needs, and I'll see what I have, and if I can help you.
Extractor? Hell no! That'll guarantee you need to buy a set of carbs. Use a Left hand drill bit, of the proper size. But be careful doing that! Mess up and you will be buying a set of carbs.
Otherwise the alternative would be to send them off to Randy. I'd bet on Randy saving the day!
Welcome Fox, sorry that your first post is a plea for help with damaged jets. If you are clever with mechanics and machines you have a chance to fix it your self. The best alternate option is to let the pros at RPM rebuild them. And let them put in the SST fastener kit to replace the soft JIS screws that Yamaha used. You might get lucky and find an Old- School mechanic that knows carbs. Many mechanics now days were born after the FJ and think they are as cool as dinosaur bones, but don't know how to work on them. When you get the chance give us an introduction, we have a section for it. Kind of like walking up to a campfire and meeting some like minded people.
Try entering your problem in Google along with fjowners.com included in the string. There were many topics covering such issues. I believe you should heat it with a torch while trying to unsrew them. Good luck!
Write something about yourself in the Introduction section when you get the time.
I've over-drilled an idle jet and used an extractor to remove it. Since the jet is brass, there's very little chance of breaking the extractor.
Success depends on how well you trust your skills, but it can be done.
Start out using a left handed bit if there's one available in the needed size.
I had the same issue tonight with 2 of mine, pretty easy all in all.
Bike has been sitting for 10 years so all 4 of the pilots were blocked and there was no way to run a 0.3mm bit that far down the hole.
Drilled them with a 3mm bit and then used an EZ-out to unscrew, had to give it a light hammer tap to start then they both came out insanely easily.
Afterwards I used a disc on a dremel to clean up the top and cut a new slot, probably going to need the EZ-out again to remove them though.
I am going to see how they go, and if I cant get a nice idle I will replace them, however I am pretty confident they will perform just fine.