The butterflies were surprisingly easy but I had the correct screw driver/bit and found it easier to use a ratchet wrench; still a bit nerve wrecking getting the screws but a magnet does wonders. No need to heat anything at all.
That's all I've got. Who's been stranded due to their PowerCommander? 
Yup...butterflies aren't bad at all if you're half-way handy. I've removed several sets now with Phillips bits and no heat, and no problems. I use a dab of light duty Loctite when re-installing.
I've never had a problem with a power commander on any bike, but I always hear people say that they are unreliable. I don't know...maybe I just have good luck.
I think a clean installation is very important. Make sure all cables, leads, and wires are kink free and mounted tightly. Make sure the wires are NOT against any metal edges where they might chafe through, and make sure the PC itself is mounted tightly with no room to move or rattle. Finally, make sure you have a GOOD ground. At least if you do all of these things, you'll remove any self-inflicted problems.
I've seen PC's just stuffed under the seat on people's bikes with the wires bent and loose all over the place. Removed an old PCIII from a poorly running ZX12R last summer and found two wires that had worn through and were shorting out. It's cases like this where people curse the Power Commander, when in reality it would have been just fine had it been installed correctly.
YMMV,
Rem
