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Discussion Starter #1
G'day

Last night I pulled off the fake chrome air cleaner cover, to pull out the battery, clean in around it and just generally play with the bike down in the shed. When I put it all back together and was tightening it up I noticed that the bolt on the bottom under the chrome bracket was simply spinning. I tried to remove it and it would seem that the metal bolt has stripped the plastic thread, thus meaning that I can not remove it now, no matter what I tried to grip it with etc.

Has this happened to anyone else and if so how can I solve this problem.

Demps
 

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Hmm....i think the threads are a brass insert which is molded into the plastic airbox and probably came loose in the plastic it's embedded in. In that case i would think you could yank the cover off and the insert should come with it. then grip the brass insert with a pliers and turn the bolt out. Then glue the brass thread insert back into the hole in the airbox. JB weld is a good product that will make it stay put. Stuff dries like steel and is impossible to break off. But anyways, this is just what i *think* has happened because the threads definatly aren't plastic. And i recall seeing a brass insert in all 2 screw holes.
 

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Hey Dazco, not sure if we are talking about the same thing. The part I am talking about and the bolt in particular is bolt number 20 in the Air Box picture you posted the opther day on the thread about blowing out the little plugs with backfiring. Are we talking baout the same thing.

Demps
 

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Yes. I'd have to look at it, but i'm pretty sure all 3 screws are anchored to brass threaded inserts embedded in the plastic. You might wanna take the other side off and look at it. As i recall there are 2 screws that hold the plastic cover under the chrome cover to the airbox, then one more that holds the chrome cover. From what you said it sounds like you meant one of the 2 screws UNDER the chrome. So i would think if you remove the one that is fine and pull the cover it should come off with the brass threads attached to the screw. Then remove the brass and JB weld it back to the plastic it came out of. Of course not being there i can't say if thats exactly whats happening, but thats what it would seem like. Of course the brass insert could have a flange on the inside end making it impossible to pull out. I just don't know. If there is a flange or something holding the insert in, you might try removing the screw thats not a problem then pull on the cover while turning the bad screw. The pressure may hold the insert from turning while you turn the screw.
 

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Did he say he will have to play with it tonight?
I think my wife said that to me once :razz:
 

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Discussion Starter #7
G'day guys,

Well I "played with it" last night and got the ***** thing out. I had to drill a little hole behind the plastic to lock the metal insert off to stop it moving around. I then could pull the bolt out normally. I then pulled the metal insert out, cleaned the damaged plastic off it and then glued it back in with structural locktite. A lot of drama for such a little thing.

Demps
 

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Thats good. I never heard of "structural" locktite, but if it doesn't hold try JB weld because that stuff is like steel and dries real quick. It'll be stronger than the plastic itself.
 
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