Merciless Carb Screws... (fixed)

[Rema1000]

I put a brand-new phillips #2 bit into a 1/4" socket, attached to a long socket extender, attached to a socket breaker bar on top.  This made a sort-of "very, very long screwdriver".  

I put the carbs between my feet (to hold them steady), then crouched/leaned over, so that the breaker bar was pressed up into my stomach.  I leaned down on it with my weight.  To turn the thing, I just sort-of twisted my torso slightly, while pushing downwards really firmly.  I didn't even try to turn with my hands.   All the screws came loose OK (first rejet, on a 12 year old GS500).

Having a long screwdriver helps keep it from wobbling very far off-center.  And having something you can really put your weight into helps keep even pressure.  You can only keep your hands just so steady.

[Gleanerizer]

Generous offer Srianth, if the only local wrench I trust doesn't pan out I'll PM you.  Even if I get this problem solved, I'd be interested in a rejet sometime later.  But for now my main priority is getting this fixed by next Friday.

I'd try your method Rema, but I'm afraid my screws are more or less goners now.  They still aren't completely stripped, but I'd rather just give up on them, at least for now.  But again, if the local mechanic doesn't work out I'll try your method before sending my carbs off.

[Gleanerizer]

Nuts... I forgot to mention this...

I said earlier that I only got one screw to give.  Well, I decided to take it all the way out to compare it to the Allen bolts I bought that day (5mm 0.8).  The replacements I got were waaaaay too big.  Those 2002 carb bowl screws are tiny.  Short too, the 16mm lengths I got woulda stuck out a couple of mm. Probably explains why there's four of those guys each carb instead of two.  Oh well, I didn't open most of the bags of bolts so I'll exchange them later.  My main focus is to get my carbs to the shop and have them get those bolts out via ANY MEANS NECESSARY (short of stripping the housing threads and destroying the carbs of course).  Hmmm, I'm out of carb cleaner, might as well pick up some and spritz it out a bit as long as I'm going through this whole ordeal... anyway, gotta go for now, gotta actually work.  Can you believe they make you work at work sometimes?

[The Buddha]

Told you they were 4mm ... and please take those bolts to the shop as well, cos otherwise they'll take out the phillips head and replace them with more phillips heads ...
Cool.
Srinath.

[denman]

take your time carb bolts are easy.   i swaped out mine with allen heads'per srinath info with out taking off my carbs+i rejeted.  see ya.

[vfrocket]

I dont know if this heps, but sometimes I have found that if you try to tightent them first a notch that brakes them free, and then it is easier to loosten... Just a suggestion.

[Gleanerizer]

OK, the shop got the screws out, I took the carbs home, readjusted my float heights (they were way off), and secured the bowls with 4 mm Allen machine bolts (sorry Srianth, I just wasn't paying attention...).  Bike runs way better now and no longer dies under hard stops.  I can ride to work again, and if my floats need adjusting again I don't have to take my carbs off.  Huzzah.