Jet Broke in carb Please Help!!!!!

[chrishonda400ex]

Ok this is not good I was going to re-jet my bike for the first time today, and when I un-bolted the 17mm bolt to get to the jet the jet fell out, well half of it! The other half with the threadsis still stuck inside the carb. I looked inside it with a mirror and it loos like there is another hexbolt it is screwed into but I could not get it out please help with suggestions.

[JRDrider22]

drill it very carefully

[chrishonda400ex]

so if I drill it should I use a sall bit and then try and unscrew the bit? I am just wondering what you think. Also I guess I will have to take the carb off the bike huh.

[blue416ex]

lol yes the carb will need to be pulled and secured in a vice then drill the jet about 1/2 way ion then try and back out and it should just unscrew if your drill has a gears like mine put it in the more tourqy gear and it should break the thing free and comon out but if it doesnt drill all the wat in it then back out or keep trying the process above then if it still wont come out drillit all the way out and get an easyout OR just pick the leftover thread pieces out with a screwdriver or tweezers

[chrishonda400ex]

So to take of the carb do I just unscrew the the carb from the manifold and take of the hoses. I know I am new to this but a detailed uninstall of the carb for a 2004 ex would be great.
Thanks in advance

[blue416ex]

loosen the clamp on the airbox side pull off the boot and push it up and out of the way loosen the clamp on the intake side (side closest tp the motor) then pull back on the carb it should pop out


BE SURE TO

shut gas OFF
pull fuel hose off carb side
either undo throttle cable up at the thumb throttle OR undo at the carb whichever seems easier to you


good luck with your problem and i hope i was a help :cool:

[Summit79]

You can buy stock and aftermarket carbs for 50 to 400+ bucks off e-bay all day long. If you're looking for a boost get yourself an edelbrock or an fcr. This shouldn't be viewed as a poblem but as an oppertunity to improve. I love it when stuff breaks.

[blue416ex]

please dont buy an edelbrock youll be sorry :(

[Summit79]

Originally posted by blue416ex
please dont buy an edelbrock youll be sorry :(

Please enlighten me.... I've never had such an awesome experience with a carberator on anything that uses carberation as it's means for fuel delivery. What was your bad experience?

[blue416ex]

friend had one messed with it for about 3 weeks and couldnt tune it correctly was always coughing and sputtering took it to a proffesional shop and they did it still had the problem slapped on my other friends fcr same size and it ran like a monter i think they are just a hassle and a half to jet and fine tune he sold it ebay and bought an cr jetted it in 2hrs and it was a "monster"
just my 2 cents on the carb

[chrishonda400ex]

Thanks for the help all, I will try this feat in the next few days, and post the results. If I break it more I guess I will buy a new carb.
Thanks again

[BSTURDIVANT]

Just take out the needle jet- the hex assy. that you were looking at! It will then screw out with a small easy out.

[rsimmons_82]

try a left handed drill bit first. it might come out with that and you wont have to use an easyout

[chrishonda400ex]

so how do I take out the needle jet I have been trying this but can't find a socket that fits. Can you please tell me how to take this out. Do I need to take off the carb?
Thanks in Advance

[BSTURDIVANT]

It would be better to at least rotate the carb so you can get to it.
The needle jet has a locknut -break it loose with a deep wall socket, then unscrew the needle jet. 8mm locknut, 7mm needle jet.

[blue416ex]

everything on the bike is metric if you didnt know but i THINK its an 8mm not positive thou and yes the carb needs to come off the bike to do everything most likely did you get out the broken off jet yet??

[brian-250]

try a SMALL flathead before you even think about drilling it.:cool:

[chrishonda400ex]

Thanks I will try this this weekend, I am working 12 hour days this week so my tie is limited but I will take te carb off and try taking off the neede jet. When I install it again is there anything I have to do special with the needle jet or anything?
Thanks for all the help guys you are great!

[2004exrider]

happened to me before, i used a small ez out and it worked pretty good.

[BSTURDIVANT]

Just snug the needle jet and lock with locknut.

[chrishonda400ex]

I got the broken jet out this weekend and now I installed a 140 jet. I will let you know how it runs in a few days.