stripped airbox nut, need help

[rubber duckie]

i just bought this bike ,749, and when i went to remove the right side air runner i noticed that the right side bolt would not come out. it looks like the previous own had stripped it and tried to fix it by drilling holes into the airbox trying to get the bolt out. not only can i not get the bolt out, he left off the front bolt on each side.

now i have to buy a new airbox, and possibly new a new runner if i cant get this thing off without breaking it.

the bike came with termi assym exhaust and has DP ecu, but not the DP air filters. looks like he went to replace it but couldnt so the stocks are still in there. why would anyone do this , be it they did the work or paid a shop to do it?

so is there a way to correctly remove this one bolt?

[kaos]

with the airbow removed you should be able to get vicegrips on the inside of the nutsert. used airboxes also seem to go for next to nothing so i wouldn't be too worried about.

[rubber duckie]

Originally Posted by kaos

with the airbow removed you should be able to get vicegrips on the inside of the nutsert. used airboxes also seem to go for next to nothing so i wouldn't be too worried about.

airbow?

[pjonte]

Problems with the runner screws are common because they are such a fine thread and easily cross thread. What usually happens is the over-molded brass insert nut spins in the plastic housing. Try drilling off the head of the screw. If the runner is being held in place by a single screw and the insert spins while drilling it pull the runner back at the same time its being drilled. This will cause the insert to spin and generate enough friction heat to melt the plastic around the insert so you can pull it out of the housing. That will leave a big hole in the air box housing. You might be able to epoxy a replacement nut in it place but it will never be 100%. I would highly recommend NOT drilling the nut-hole through to the interior, as this may allow the nut to come off and get sucked into one of the throttle bodies -

This may allow you to at least remove the top off the air box for replacement without having to remove the whole air box assembly. Dealing with the fuel lines on the lower housing is a PIA.

To remove the upper housing remove the screws around the perimeter, there are three in front and are a bitch to remove, especially the one in the very front, but it can be done, might need to loosen the hose clamp fixing the front throttle body. You'll also need a long skinny Phillips head screw driver.

As Kaos noted it may be easier to replace the upper housing than dick with trying to patch the one you have - just make sure the replacement isn't jack too.

Hope this helps, I just went through the same problem but luckily the threads were only stripped and was able to repair it with a helicoil.

[rubber duckie]

Originally Posted by pjonte

Problems with the runner screws are common because they are such a fine thread and easily cross thread. What usually happens is the over-molded brass insert nut spins in the plastic housing. Try drilling off the head of the screw. If the runner is being held in place by a single screw and the insert spins while drilling it pull the runner back at the same time its being drilled. This will cause the insert to spin and generate enough friction heat to melt the plastic around the insert so you can pull it out of the housing. That will leave a big hole in the air box housing. You might be able to epoxy a replacement nut in it place but it will never be 100%. I would highly recommend NOT drilling the nut-hole through to the interior, as this may allow the nut to come off and get sucked into one of the throttle bodies -

This may allow you to at least remove the top off the air box for replacement without having to remove the whole air box assembly. Dealing with the fuel lines on the lower housing is a PIA.

To remove the upper housing remove the screws around the perimeter, there are three in front and are a bitch to remove, especially the one in the very front, but it can be done, might need to loosen the hose clamp fixing the front throttle body. You'll also need a long skinny Phillips head screw driver.

As Kaos noted it may be easier to replace the upper housing than dick with trying to patch the one you have - just make sure the replacement isn't jack too.

Hope this helps, I just went through the same problem but luckily the threads were only stripped and was able to repair it with a helicoil.

thanks, i did find another complete airbox and planned on replacing it. well the front screw was already off when i got the bike, i was trying to take off the 2 front ones on the sides, but no luck. if i cannot get the top off without taking out the airbox, i will be replacing the entire thing.

[Dennie]

If you're planning to buy a new air box, maybe you can buy the bigger carbon air tubes. I have a set left. Send me a PM if you're interested.