Like the title says, when I removed the plugs one of the threads has a nick in it...

The mixture screw gets tight when I back it out to the damaged thread, predictably.

If I force the screw to come out will I ruin something?  I suppose if the material of the screw is hard enough it will fix the threads in the aluminum... ? What material are the screws made from?

Can you back the mixture screws out enough for rejetting? About 3 turns max? If so, I wouldn't worry about them too much right now. The only reason to fully remove them is if the needle tip is broken (from excess tightening) or if the carbs are absolutely disgusting and need cleaned out (think full of gas for 20 years and sitting in a barn the whole time).

Yeah I have plenty of turns to work with, the damage is on like the second thread from the end.  So I'm not too worried about it.

I removed the mixture screw from the other side and it looked clean so I assume the other is going to be clean as well.  I wish I could inspect it directly, though

Screw is steel, carb wall is cast aluminum like junk. If it will fix itself ... depends on how much damage there is.
But in real life - You don't need to remove the screw, you need to seat it light and count 3 turns out from there.
Anyway I've seen people nick the screw head - how you hit the wall

Cool.
Buddha.

Idk how I hit the wall.  I used a pick to see if I could pull the plug once I broke through, maybe the tip of the pick hit the thread? 

Now that I look at it with a flashlight that seems to be the case, the drill did not hit the threads, there is a vertical scratch in the threads.

Whoops!

Quote from: lucas on October 10, 2015, 02:26:12 PM
Idk how I hit the wall.  I used a pick to see if I could pull the plug once I broke through, maybe the tip of the pick hit the thread? 

Now that I look at it with a flashlight that seems to be the case, the drill did not hit the threads, there is a vertical scratch in the threads.

Whoops!

Oh yea, you're a regular gorilla.
However you are likely to have that scratch "fixed" when you unscrew it. Just use penetrating oil or other lube, don't dry fruck it again.
Cool.
Buddha.

At this rate I should have just taken my money and went to one of those motorcycle technical schools.  Someone stop me before I ruin more crap.  These lessons are getting expensive.

I tried to back the screw over the damaged threads and only made it much worse.  Now the screw is extremely difficult to turn and the slot of the screw is showing signs of rounding off...

Are there special screwdrivers for slots like this?  All my screwdrivers are tapered and it seems like a screwdriver with parallel faces would be better for this.

Doesn't matter I guess, I think I hosed these carbs.

Quote from: lucas on October 10, 2015, 06:53:22 PM
At this rate I should have just taken my money and went to one of those motorcycle technical schools.  Someone stop me before I ruin more crap.  These lessons are getting expensive.

I tried to back the screw over the damaged threads and only made it much worse.  Now the screw is extremely difficult to turn and the slot of the screw is showing signs of rounding off...

Are there special screwdrivers for slots like this?  All my screwdrivers are tapered and it seems like a screwdriver with parallel faces would be better for this.

Doesn't matter I guess, I think I hosed these carbs.

yes   that's  how we learn  ,  from  mistakes  , nobody  is perfect  ,   I  hit a brick  on the road  (dark night )   rim from partzilla   front rim  $  450.00   plus  new Suzuki  bearings  and  had to wait  a  month  ( no  new  rims in  stock  in the  usa )    so   my mistake  was  $$$   

That 3 threads from the bottom are no big deal. You get the screw all the way out If not, you are fine, put it back in and 3 turns from lightly seated.
You should only do 1 thread and go back in to look at what it did.
That is not a regular size that you can get a tap and clean it up. I think its 6mm but fine thread. Measure and find the tap for it. Then learn how to tap it and then tap it. Plenty of lube, in 1 turn. out 1/4 turn, etc etc ...
I'm sorry man, I didn't think you were going to take it out. And if you started chewing the slot, I'd have stopped.
Cool.
Srinath.