To get the broken head bolts I would recommend an easy out. You can get then at most hardware stores or sears. they are like a reversed drill bit so they bring the bolt out with them

 

I know exactally what bolts you are talking about. My 300EX is the exact same way I've probably broke off 3 bolts. I don't think they make and easy out that small those things are smaller than 1/4". Your next option is to drill out and re tap it would make it as good as new. Some guys will drill bigger and install a heli coil. I drilled all myn out and converted to american 1/4" lots stronger.

 

400ex's arent that bad because my friends warrior falls apart 24/7 so personaly i think warriors suck beside what do you more in mx warriors or 400ex's ? yamaha need to come out with something new becuase the blaster warrior and the banshee arent that good any more. i saw a lakota outrun the blaster and the warrior sorry dude but the 400ex is better

 

For removing broken off bolts I always use a heli-arc welder. Just weld a small piece of rod to the broken bolt, let cool 15 seconds on twist the rod out with a vise grips. You can also weld a nut to the end of the rod to use a socket or wrench for twisting. Works every time for me. Karl

 

Stripped or broken head bolts on 400EX's is a common problem. Once they've been disturbed, they need to be replaced. My advise at this point would be to send the jug to Sparks racing and have them do their larger stud upgrade. It only costs about $25.00 and your head gasket problems will be a thing of the past.

 

It took you guys 10 hours to replace a 400EX head gasket[img]i/expressions/face-icon-small-confused.gif[/img]

(ps. Ive done it, and I stripped one too...)

 

man i go ballistic when a bolt breaks off or strips, and Honda is famous for it, including their cars.

i believe in Harley/Davidsons philosophy, similar to john deere's ;
harley has only three rules, and no stripped bolts.

1. it's not loud enough
2. if it breaks, make it bigger
3. if it sticks out, chrome it!

American engineering philosophy on wheels. hey theyre selling arent they? [img]i/expressions/face-icon-small-happy.gif[/img]

 

So far, i've broken 2 head bolts on my '77 honda odyssey, So i guess honda really does have a problem with weak bolts.

JaMeS

 

What can you expect from a manufacturer that makes a atv in the year of 2003 and doesn't have a reverse on it.

 

Well then, screw Yamaha, Kawi, bomb, cannon, AND honda? right???

Thats one of the most rediculous posts in a while.

-Matt