after reshimming the kx and setting the timing correct i started torquing the bolt to 12n.m /100ish lbft / 8ftlb and after following the tightening sequence they seemed to never tighten, 2 of the bolts snapped at 4nm a mile away from 12? wots happening am i doing something wrong? Ive ordered new cap bolts and the thread seems fine but wondering wots going wrong has any one else had this problem?

they should be torqued to 104 INCH pounds not Foot pounds . you torued them twelve times tighter than they should be.

Quote

make sure you are using pound inches. if you are check your torque wrench for accuracy, that could be the culprit. It sounds like something is mking you tighten the bolts much tighter than they should be.

looks like the wrench my friend lent me wasnt from 2-9 n.m but 20-90n.m!!!!

Im not sure what the 2004 is but I have a service manual for a 2005 rmz250 and it is supposed to be only 87 inch pounds. That is only something like 7.2 foot pounds. It is a very light torque rate. If you went higher then that you probably striped out the threads. Not sure if it would work but you might try to drill out the holes and heli coil them. The only other fix is to buy a new head! That is about $500, give or take a few bucks. I can tell you that dealer cost on a new head is under $300 if you can get your dealer to work with you. Hope this helps and good luck.

Torque 84 INCH POUNDS...no more... If you need to buy a new head, get a 2005. We can sell you one for $325.00 US Dollars. We sell them for just over $410.00 here in Candian dollars. Email me if you want one.