A plugged pilot jet can create an unstable idle (also called hunting idle) issue that may act like a choke issue. If you believe a plugged pilot jet is affecting the performance of your generator, follow the cleaning process in this article. This process includes removing the pilot jet and retaining cover located beneath the idle adjustment screw, which is pictured below.
Required Tools and Supplies:
- Safety Glasses
- Nitrile Gloves
- Phillips Screwdriver
- Flat Blade Screwdriver
- Fine Wire
- Carburetor Cleaner
- Compressed Air
Always wear safety glasses and nitrile gloves when servicing a Polaris generator.
1. Remove the idle/pilot jet. Note: The removal procedure differs by carburetor. Refer to the tables below for the correct removal procedure.
| CARBURETOR PART NUMBER 2208685 | |
| The idle/pilot jet is located underneath the retaining cover. The screw and cover need to be removed to access the jet. To remove the jet, lightly pry upward, removing it from the carburetor body. | |
| (A) Retaining Cover and Screw | (B) Idle/Pilot Jet |
 | |
| CARBURETOR PART NUMBER 3410408 | ||
| The idle/pilot jet is located below the idle adjustment screw. The idle adjustment screw will need to be removed before removing the idle/pilot jet. To remove the jet, lightly pry upward, removing it from the carburetor body. | ||
| (A) Idle Adjustment Screw (B) Idle/Pilot Jet | (C) Idle Adjustment Screw (D) Idle/Pilot Jet | |
 | ||
2. Once the idle/pilot jet has been removed from the carburetor body, use a thin wire to carefully clean the jet’s orifices. Carburetor cleaner and low pressure compressed air may be used to assist with cleaning. Do not use torch tip cleaners or any abrasive tools. Abrasive materials can enlarge the orifices, allowing excessive fuel delivery at idle and resulting in idle issues.
3. Inspect the O-ring(s). There are slight differences in the idle/pilot jet design between the two carburetors. As shown below, carburetor part number 3410408 uses two O-rings on the pilot jet that must be carefully inspected for damage. If either O-ring is compromised, an air leak can occur in the idle circuit. This leak will create a lean air fuel mixture, resulting in an unstable or hunting idle.
4. If cleaning the pilot jet and carburetor does not correct the idle issue, replacement of the carburetor assembly may be required.
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement parts, use the online parts catalog.
Unless noted, trademarks are the property of Polaris Industries Inc.
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