We own 4 (2000 & 2001) Magnum 500's and are noticing that the 1/4 Bolts are breaking off. These bolts are found holding the skidplate, rear brake bracket, the Dry Sump tank support below the tank and in other areas. Each bike is experiencing the same problem. These bolts all have the letter "S" on the head. All bikes are new and have very low mileage 80 - 300 miles.
Anyone else noticing this problem ????

 

I have noticed that the screws that hold the plastic on the floorboard to the metal bracket underneither do come out, make sure that you tighten these or they will come out, or atleast mine did.

 

Yes, I have hade the same problem. I broke both bolts holding the bottom of the bashplate. Those bolts are less than a grade 2 bolt, I relaced all the bolts in the skid and bash plates with grade 5 bolts from the local hardware store. When you install the new bolts, be sure to coat them with a good antiseeze compound and DO NOT over tourque.

 

I had a new 400L I took out of a crate that had a couple broken bolt heads in the bottom of the crate . I suspect the bolts are put in with air tools preset for the job . It may be a combination of wimpy bolts and a little to much torque at the factory . The factory bolts are *glorified self-tapper* type , but the grade 5 *normal* bolts will go right in for sure. I think Soggy Rider has the right idea .