crappy airbox!

[PedroHM]

So, fitting the DP airbox lid, was prepared for a total mare of doing it but to be honest it was not that hard and I had the tank out the way in about 20 mins and propped up on the left handle bar. bolts easy to get to with an allen key on a small 8mm socket, no worries.

But then, 2 bolts seem very tight and it feels like the socket is slipping and tearing the head of the bolt to shit, try a few different ones and the same, the i look closer and the head has been turning all the time and the metal insert (at a guess there is one) is spinning inside the plastic, i can feel it grip and release when turning. There is no way without total destruction to get the bolt out.

Pretty bad for a 'user' serviceable part like checking air filter! I'll be hitting up the dealer today for a new airbox on warranty or a fix but i can't see how its fixable with 2 bolts are the same.

pi$$ed off now.

[barneybarn]

I've noticed regardless of which Ducati you have, they have some serious bolt issues. I can't eplain how many I've stripped, spun, and/or destroyed. It's not you brother.

[AXE]

I had the same problem. I think they are overtightened at the factory and you strip the brass nut out of the plastic housing when pulling them out.

I was actually able to pull my bolt and nut out of the plastic housing. Once I did my filter swap, I decided I was going to do one of two things to repair it. The first thing I did was lightly heat up the brass nut with a torch (not super hot as it will burn through the plastic top). Then insert it back into the hole in the airbox. It should melt the plastic slightly and give you a solid mount. At least it did for me.

My second option was to get some Devcon two part 5 minute epoxy. I have used this in the past on plastic motorcycle parts where aesthics are not a concern. This shit will form a permanent bond to that plastic and will be hard enought to allow you to slightly tighten the screw.

These things are so sensitve, that anything more than hand tight plus a little and you are gonna have problems.

Out!

[PedroHM]

yeah, if it was 1 could pull it off and prob get the insert out, but its 2 bolts and I'll just end up destroying it doing that and then i have no chance of a swap. its ok for now so can run with it till i hear more.

[johnchypermotard]

the airbox threaded insert issue happened to my hypertard as well when replacing the airbox lid. pretty simple to fix:

1. pull the insert out of the airbox plastic (with the bolt and lid, if necessary)

2. remove the bolt from the insert

3. clean out the hole in the airbox where the insert sits

4. clean off any extra plastic from the insert "barbs"

5. apply liberal amount of two part epoxy into the insert hole in the airbox

6. screw the bolt into the insert, then apply epoxy to outside of insert

7. place insert into hole in airbox, straighten up the bolt/insert so aligned properly, and let epoxy cure

8. when epoxy is fully cured, remove the bolt

9. install airbox lid, and apply small amount of anti-seize to the bolt threads to insure they will not seize again (pulling out the inserts once again)

ciao,
johnc

[GMP]

This happened to me late last night with one bolt, but they were all too tight. Ducati should invest in a torque screwdriver for the assembly line. I had the tank loose in front and lifted just enough to get small 8mm on the bolts, but not enough to extract the spinning bolt. I guess I'll have to pull the tank completely and remove/repair when I have more time this weekend. What a PIA just for filter access. I also did the LV CAT eliminator, what a breeze compared to the DP aixbox lid attempt. I anticipated issues with exhaust work but it went easy. No leaks, runs great with a bit more sound from the stock mufflers. No need for that heavy heat source under the swingarm.

[dukepilot]

The best place for the airbox is in a box in your garage. Its too small and restrictive. See Intake and Fuel Injection/Ignition Mods - Part 1

[scottysspeedshop]

Yep the Beast R rocks

[GMP]

Yes, I like your setup, but for now I'm still running the stock ECU and can only go so far. The bike runs decent, no surging or stalling and no popping on decel. So far I have the flapper disabled with a travel limiter plate on the motor and the LV CAT eliminator. Still waiting for the special closed loop version of the Powercard, when I get that and save a few more $$ I'll do the LV slip ons and perhaps the pod filters.

[yota]

I was lucky, mine all came out easy. I've had this problem with inserts on mx bike fuel tanks, ruined a yz tank. when you do get them out, put a small amount of grease on the threads and you'll never have the problem again. brass and steel do not mix well.