I'm working on an extra pair of carburetors I have for my 04gs500f.  The screws on one float bowl were stripped, and I got 3 of them with vice grips.  The last screw is surrounded by "stuff" - the bowl, the bar at the bottom of the carb - so that I can't get vice grips in there to grip it. I tried PB blaster.  I tried cutting a slot with a dremel, but don't want to get it so deep that I lose the head on the screw if it strips, and can't get a bite on it otherwise.  It's too small for an extractor.  Anyone have any suggestions?

If there is still any of the phillips head left, try a hand impact driver.  Not only is the shape of the head better (on my cheap set from Harbor Freight) but the impact sometimes does the trick.

Once you get it off, put on allen head screws.  If you can't find them locally, see my signature line or check the board for other people who sell them.  If you want to get it back on the road sooner, swap the screws from the bar onto the float bowls and vice versa, then change them later.

same thing happened to me but i was still able to get it with vice grips. just grab it with the vice grips at some crazy angle, and try to rotate it as much as you can. i was only able to get maybe like 3 degrees of rotation, but it was enough to break the siezedness (made that word up) of the screw. then i was able to get it with a screwdriver.

As a last resort, it should be possible to grind off the head with the Dremel. Be careful not the damage the float bowl. You can then remove the float bowl and extract the stud with Visegrips. If you have not already done this, you will probably want to use penetrating oil on the stud before using Visegrips.

Don't grind off the head you best bet is to get an extracter you use on the drill it looks like a flathead screwdriver bit but its a drill bit you put the drill in reverse and it will drill the inner head out and once it hits the screw shaft it will pull the screw out I did that with 6 of my stripped screws then I just used 832 screws and now they are good,

Quote from: mach1 on November 27, 2008, 02:09:01 PM
Don't grind off the head you best bet is to get an extracter you use on the drill it looks like a flathead screwdriver bit but its a drill bit you put the drill in reverse and it will drill the inner head out and once it hits the screw shaft it will pull the screw out I did that with 6 of my stripped screws then I just used 832 screws and now they are good,

The threads aren't 8-32, they are metric.  I'm not at home or I'd give you the size.  But definitely metric.

I'm pretty sure an M4 thread setup would be correct.  not 100% but I think thats what they are.    4x12 is the numbers I found on bikebandit, and I'm 99% certain most every carb uses the same screws.

oh i didnt mention i redrilled a used helicoils.

Quote from: mach1 on November 28, 2008, 10:51:42 AM
oh i didnt mention i redrilled a used helicoils.

That WOULD make a difference.   

Don't know if it would help you gain clearance but vise grips are made in needle nosed versions also.

Quote from: commuterdude on November 28, 2008, 06:30:10 PM
Don't know if it would help you gain clearance but vise grips are made in needle nosed versions also.

I won't lie - I had never seen needle nose vice grips before, but 40 seconds into owning a pair, problem solved...  Thanks.

Hey had the same problem, i got it out with easy grip i think it was called? Basically reverse screw.  But where can we buy new screws at?

Quote from: wesdabest787 on December 04, 2012, 07:53:00 PM
Hey had the same problem, i got it out with easy grip i think it was called? Basically reverse screw.  But where can we buy new screws at?

Part number 31 - $4.03

http://www.cheapcycleparts.com/model_years/4437-suzuki-2007--gs500f/assemblies/125027-carburetor

I don't think he was referring to the drain screw.  From the wiki:

Carb Float bowl bolts - 5mm x 12mm; 2002--4mm X 0.7mm 10mm length

I'd recommend stainless steel socket head cap screws (also called allen head).

Also by the way...it looks like ronayers.com is cheaper than cheapcycleparts.com on both parts and shipping.

$3.34+$8 shipping = $11.34 from ronayers
$4.03+$9.99 shipping = $14.02 from cheapcycleparts

You do realize that this thread is from 2008 right?

Quote from: wesdabest787 on December 04, 2012, 07:53:00 PM
Hey had the same problem, i got it out with easy grip i think it was called? Basically reverse screw.  But where can we buy new screws at?

I was just trying to answer this question that was raised recently.

I know this thread is super old, but I just wanted to say thanks for helping me. I was finally able to get my float bowl and drain screws unstuck, and also was FINALLY able to find a place to buy new ones...

I found 3 places that have parts and I'm bookmarking all of them. I'm posting this for anyone who might be looking for carb parts, drain screws, basically anything. And I'm sure a lot of you are aware of these places, but I was not and have been struggling with google trying to find parts:

cheapcycleparts.com
ronayers.com
partzilla.com - i ordered from here as it had the cheapest shipping, but all 3 shops had a ton of GS500 parts.