Hello All

I'm new to this and posted my quesxtion in the wrong place. I recently traded for a 77 XS400 that was mostly in parts. I'm a retired auto mechanic and have some mechanical ability, so it didn't take long for me to get it up and running with a little aid from a used Yamaha manual. I want to change the handlebars and have been unable to get the screws out of the right side switch assm. The heads were torn down to nothing from someone else attempting to remove them. I cut a slot across the screw with a cutoff wheel on a Dremel tool but that just made things worse. I've been looking for a photo of the assembly apart or a diagram to see if I cut the head off will I be able to get it apart and have enough screw left to work with, but can't find anything that helps. I'm sure someone has had these apart and remembers how they are made! Any Help Will Be Appreciated

If you look where the 2 sections of the switch assembly you can see where these part (once you get the screws out) join. You can normally gauge how much of the bolt will be left once you cut the head off by looking at the distance between the bottom of the bolt head and the where the 2 sections join.

+1 with that, I would think there will be something left to get some mole grips on if you drill the head off

Thanks for your help guys. I was able to cut the heads off with a cutting wheel and remove what was left with visegrips. I was surprised to discover the screws were 10-32 machine screws, not metric. I should be able to get them at the hardware store tomorrow. Thanks again

they are usually 5mm, are you sure about that?...doesnt sound right at all to me so surprised...rightly so

by the way...you can determine the size from the part number if you check