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Carb pilot screw issues (please help) #153361 06/12/22 10:45 PM
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TamirG Offline OP
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I have an '06 XT 225 and can not get it running right. When I bought the bike (2 years ago) I had to have the pilot (mixture) screw drilled out because it wouldn't turn. The shop that drilled it out sent me home with a titanium screw as a replacement. I also ordered an OEM brass screw. I have the original screw that was drilled out and it's identical to the brass OEM I ordered but both are different from the titanium screw. The differences are subtle but the shaft close to the tip has more of a "slope" than the OEM screw.

Here's what's interesting: the titanium screw turns in 14 full turns until it's lightly seated. The brass screw can only go in 2.5 times before it's seated. I can't turn out the brass screw more than one turn before it becomes really loose and the engine vibrates it out. Today the screw came out and I've lost the spring.

I have tried multiple set-ups with the titanium screw (3 turns all the way to 7 or 8 turns, with every 1/2 turn in between). I can not get it to run right. Hesitation and bogging in the low gears. Choppy/rough sounding idle.

I have ordered a carb rebuild kit on eBay, waiting for it to arrive. I imagine the new screw will be similar to the OEM and only turn in a couple of times. I'm so frustrated, ready to give up and get a scooter. What else can I possibly try? New jet sizes? I'm in South Florida. I've adjusted the float to make sure it's within spec. How many turns should it take to lightly seat the OEM screw? Can't find that information anywhere.

Any help would be greatly appreciated.

Last edited by TamirG; 06/12/22 10:46 PM. Reason: Changed title
Re: Carb pilot screw issues (please help) [Re: TamirG] #153362 06/12/22 11:28 PM
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peejman Offline
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The tip geometry would have to be hugely different to make that big of a difference in the turns. Something else has to be in play. Does the screw also have the washer and o-ring installed? Got a pic of the titanium screw?

What you need to figure out is if it's rich or lean as you can get similar symptoms when it's way off in either direction.

Pay very close attention to the intake boot and the plastic covers on the sides. They can crack when they get old and cause major fueling problems.

Last edited by peejman; 06/12/22 11:31 PM.

This shall pass, be still and know.
2006 XT225, UNI filter, ProTaper bars, MSR handguards, SS front brake line, Shinko 241's.
Re: Carb pilot screw issues (please help) [Re: peejman] #153363 06/13/22 12:15 AM
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TamirG Offline OP
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Thanks for the reply. Here's a picture of the two screws. [img]https://postimg.cc/bsyd6nY3[/img] (was hoping this image would attach here directly)



Interesting point about the manifold boot. I've taken off and reinstalled the carb at least a dozen times and I find placing it on the boot and the air box throat to be the hardest part and perhaps I've been less than gentle.

Re: Carb pilot screw issues (please help) [Re: TamirG] #153368 06/13/22 01:01 PM
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peejman Offline
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[Linked Image from i.postimg.cc]

The taper difference is enough to cause the number of turns to be potentially very different. It's possible that screw could be made to work, but will take some effort to figure it out.


This shall pass, be still and know.
2006 XT225, UNI filter, ProTaper bars, MSR handguards, SS front brake line, Shinko 241's.

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