BS34 Carb pilot jet plug

You two guys must be talking about 2 different plugs. The rubber plug sticks in the hole of the pilot jet, theres no way to put it in that makes it difficult to remove, its a little rubber plug with half of it sticking out. Are you maybe talking about the aluminum plug over the mixture screw ? A place called www.cycleorings.com sells a o-ring kit for $14 that covers the whole carb, {it says Suzuki but they are the same carb}. www.mikesxs.net/products-35.html#products this place has the rubber plugs 2 for $4{ these say XS650 but are the same thing too}

I hope not! The two different plugs you mention (the pilot jet plug and the pilot screw plug) are shown/discussed w/pics at:

forums.somethingawful.com/showthread.php?threadid=3017242

But my 1982 KZ1000's pilot jet plugs are indeed metal with o-rings (the pilot jet plug is located inside the float bowel) - not rubber as some are (including the ones pictured in the link). Search on part number 92066-1087 at ronayers.com for the plug, and 92055-1059 for the o-ring (part numbers from kawasaki.com under owner info, part diagram for your scoot).

All the pilot screw plugs (located on the outside of the carb) were missing from my scoot since I got it about 20-years ago.

82kz1000P wrote:

But my 1982 KZ1000's pilot jet plugs are indeed metal with o-rings (the pilot jet plug is located inside the float bowel) - not rubber as some are (including the ones pictured in the link).

The pilot jet plugs in the BS34s I have on my GPz 1100 are also metal, see the pic below. Not sure which bike the carbs came from (GPz 1100 is born with FI), but some po installed the plugs so deep that all four are completely stuck and impossible to get a grip on, my only option is to drill a hole in them and insert a self-tapping screw in them to hopefully pull them out - I need to know what size pilots are in there plus I absolutely hate parts being stuck on my bikes.


I was told the rubber plugs are a straight swap for the metal plugs, at $ 9 for a set of four I'm willing to give it a try.

These BS34's were designed so the pilot jet draws it's fuel thru the main jet. The early KZ style BS34's use a metal plug with an o ring. The early, if not all, Suzuki style BS34's use the rubber plug. The plugs will interchange. If you look at the inside of the float bowl you will see a cast in stop that prevents the plug from falling out. The pilot adjustment screw has, as stock, a thin aluminum cover to prevent adjusting the pilot screw.
Also, that pilot screw cover prevents dirt from getting into the pilot screws threads. On most other carbs there is an o ring above the pilot screw threads, relative to the screw head. The BS34's place the o ring below the threads just above the needle tips.

Like i said,"i'll pull the carbs and install the plugs later".

I'll ask the guy on the "Mark" bike i blew off saturday if he thinks i need to install the plugs.

I am going to do his carbs and i could set his bike up diffrent than mine and we can compare.Roy

but some po installed the plugs so deep that all four are completely stuck and impossible to get a grip on, my only option is to drill a hole in them and insert a self-tapping screw...

My pilot jet plugs had a shoulder, so there's no way to sink them in as someone did to yours; the rubber plugs also have a shoulder. Maybe use a drill press if you have access to one.

I used a small drill and a pick to remove mine. Roy

MY bad I posted that the pilot screws on BS34 have the o rings below the threads. Correction..the Kawasaki BS have the o ring above the treads, the Suzuki BS has the o ring below the threads. Sorry, for the misleading info. The BS style Mikuni's do need the cover on the pilot jet opening to properly control the fuel mix thru out the RPM range.

If you buy the correct rebuild kits for the particular carbs you have, the proper plugs will come with them. Some will come with all rubber plugs while others will come with steel plugs that have "O" rings on them. Despite all of this, there is a reason why the parts are where they are and why they are there. Changing sizes of something is one thing but discarding a part all together is never wise. Unless of course you are an engineer and can compute the consequences.

If you look at the carb there is a small hole near the top that connects the the two passages between main jet and pilot jet if the hole is there you need the plug if not you don't