My pilot jet keeps getting clogged.

333 Views 8 Replies 7 Participants Last post by webb68918, 1 d ago

madmatt321

Discussion Starter · 1 mo ago

Hey guys, my pilot jet keeps on getting plugged on my bike. It sat for many years before I bought it so it had bad gas and a rusty tank. I cleaned the tank completely, put in new gas lines, added an inline fuel filter, and cleaned the carb. I got the bike to fire right up. It idols fine but as soon as I rev it up it bogs and sputters and then dies. If I pin the throttle I can skip the pilot jet and get it to rev high but as soon as I let off it sputters out. I have taken the carb off 5 times now and everytime the pilot jet is partially plugged, but it has never been fully plugged. That is why it will still idol, but it doesn't get enough fuel when I give it more throttle. After I clean out the jet and put it back in, it gets instantly plugged.
I'm out of ideas and would love any advice or ideas. Thanks.

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Slorg442

· #2 · 1 mo ago

Residual debris left in the lines.
Didn't get all the trash out after cleaning the tank.
Inline filter still allowing particles to pass.

What type of material is clogging the jets? Is it sludge from old gas?

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madmatt321

Discussion Starter · #3 · 1 mo ago

Slorg442 said:
Residual debris left in the lines.
Didn't get all the trash out after cleaning the tank.
Inline filter still allowing particles to pass.

What type of material is clogging the jets? Is it sludge from old gas?

I haven’t been able to tell because it is so small. Do you think I need to clean my gas lines somehow?

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Slorg442

· #4 · 1 mo ago

Anywhere particles can collect. Chokepoints, low points, restrictions.
If your tank was dirty and was run, you have/had trash everywhere. Including the fuel pump.
Flush the system. I extend the fuel line into a gas can, put it in first gear, and hold down the starter button to run the fuel pump. Jiggle the bike, lean it to both sides.
I don't know how you clean the carbs, but an ultrasonic cleaner works well, along with compressed air.
This is one of the reasons rusty tanks are a nightmare if not cleaned and lined properly.

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2fat2fly

· #5 · 1 mo ago

Clean your entire fuel system. Disconnect everything and start with the fuel tank. Any debris in there will make its way to the float bowls. Get it completely clean then clean or replace the fuel lines. Replace the filter and then clean your carbs. Just because of the nature of the beast, you may have to clean your carbs multiple times to get everything out.

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Hammerhead

· #6 · 29 d ago

I've cleaned a few rusty tanks. My method is a gallon of Evaporust and a handful of nuts and bolts. I used to have a stash of brass hardware, but anything will work. Shake it like a Polaroid picture and let stand overnight. Turn over and repeat. When you peer inside and it's clean, you're done. Fill with fresh fuel asap.

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92Ninjas

· #7 · 29 d ago

Pilot jet affects idle to about 1/8 throttle. Your jet needle is from 1/8 throttle to about 1/2 throttle. Main jet is from about 1/2 throttle to WOT. So, if it runs like crap in between idle and WOT, your emulsion tubes are getting clogged with crap from the tank. I agree with everyone else here. Re-clean the tank, seal the tank, flush the fuel pump, re-clean the carbs, install new fuel lines if they're too far gone and new fuel filter.

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Blainethemono

· #8 · 13 d ago

Take off your gas tank, drain it, pull the petcock & replace ALL lines, including internal tank filters. Be on the look out for small black specs. This is the OEM fuel lines DECOMPOSING, which will clog your pilot jets...

Been there, Done that...

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Reactions: 2

webb68918

· #9 · 1 d ago

madmatt321 said:
Hey guys, my pilot jet keeps on getting plugged on my bike. It sat for many years before I bought it so it had bad gas and a rusty tank. I cleaned the tank completely, put in new gas lines, added an inline fuel filter, and cleaned the carb. I got the bike to fire right up. It idols fine but as soon as I rev it up it bogs and sputters and then dies. If I pin the throttle I can skip the pilot jet and get it to rev high but as soon as I let off it sputters out. I have taken the carb off 5 times now and everytime the pilot jet is partially plugged, but it has never been fully plugged. That is why it will still idol, but it doesn't get enough fuel when I give it more throttle. After I clean out the jet and put it back in, it gets instantly plugged.
I'm out of ideas and would love any advice or ideas. Thanks.

I used spray can's of carb/throttle body cleaner, & a 10 foot length of fishing line with clean cotton rag wads small enough to drag through the fuel lines, tied at every 3 inchs & just spray & pull through over & over until content reem cleaned, plus i also did that 3 stage de-rust, clean, & poly line fuel tank kit too, & from a same as your drama, it's now faultless.

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