I needed to re-jet (because I installed a slip on Yoshimura pipe) so I started by loosening the clamps and turning the carb to it's side exposing the screws.
I got a ratchet and screw driver bit (of correct size) and started to loosen and low and behold striped head, I tried the next one and the next, they all stripped - weak *** metal.
I removed all the lines from the carb except for the throttle cable and thats my problem how do you remove it?
And now that the screws are stripped how do you go about removing them ?
Vise grips are to big in most cases, making a flat screw driver slot causes metal that could get into the carb inside.
Any help would be great.
Thanks again.
Steve

 

To remove the throttle cable, take off the side plate which has 3 screws on the right side of the carb. Rotate the cam forward and remove the round keeper. Then loosen the cable housing on the outside of the carb where the cable enters the carb.
If you can't get off the screws with vise grips just use a dremel and grind some grooves in the head to fit a flat blade screwdriver in there and press down hard when turning it. Replace the screws with stainless allen head bolts. There are (3) 4x10mm & (1) 4x12mm. I did my top cap as well, those are 5x10mm.

 

When I was in the service back in the 80's I was a cobra helicopter crewchief and there is 1000's of phillips screws holding the structural panels on and when they were stripped alot of times we would have to use some good old fashioned ajax on the screwdriver bit, dip the tip of your screwdriver into something wet and then dip it into the can of ajax something about the grittyness of it helps not always but most of the time, hope this helps you out somewhere on here i was looking at pics that discribed this in detail but forgot where it was sorry

 

JMAC650 did what I did you can also take a die grinder and take the heads right off , then take the bowl off then w/ a pair of vice grips and turn out the studs. it seams all the carbs on the ds are like this.

 

It seems to be a very common problem. I had the same thing happen to both the float bowl and the faceplate where the throttle cable attached. I ended up drilling it out with a slightly smaller drill bit and then using a EZ-out to remove the screw. I never like Phillip head screws and can't for the life of me figure out why any quad or motorcycle would ever use them. I switched them out to stainless steel socket head cap screws.....

 

i always broke the screws loose when the engine is nice and warm, seems to come loose alot easier then replaced them with allen head screws.

 

First thing first - THANK YOU EVERYBODY.
I still have questions though!
How do you remove the cable from the cam, I tried to pull the pin out and it would only goes so far, do you have to remove the throttle cable housing from the carb - I believe it has two allen head bolts/screws?
Please respond ASAP thanks again.
Steve

 

if I remember right you need to hold the butterfly open a bit get some slack in the cable and get some slack in where the cable attach's to the carb and unattached it. you might need to open the thumb throttle cap and un hook it there so you have some slack to work w/. some one jump in here if this is wrong its been 2yrs since I did this.

 

Rotate the cams to full throttle and you will see the cable come out of the groove. Just remove the cable and the round stopper will come out. Then remove the cable from the stopper. It sounds confusing but once you take it apart you will see it is quite easy.

 

I used small needle nose vise grips (purchased at Home Depot) to take off the float bowl screws. Just clamp on and break them loose. Replaced with the allen head screws mentioned earlier. Makes things much easier. By the way, I don't think its necessary to take the carb off to re-jet.