How to fix a broken threaded air box insert

Jetting and intake information
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Sandblaster
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How to fix a broken threaded air box insert

Post by Sandblaster » Fri Nov 02, 2012 10:21 pm

How to fix a broken threaded air box insert.
Nothing is worse then trying to remove your air box only to have the steel threaded insert break off the plastic box.
In my case, my 01 KX500 air box had one of the metal threaded inserts completely gone :cry:
The air box is P/N 11011-1304 and fits 89-04 KX500, 89 KX125 KX250.
The retail price as of 11-2-12 is 105.75 USD without any of the attachments.
So, I would much rather repair it if I can do a good job.
Here is the broken insert:

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I rummaged around in my warehouse and every air box that I found was damaged to one extent or another.
Go figure, a 500cc 2 stroke throwing huge rocks, sand, and gravel at the air box for the last 12 years :shock:
So, I took another air box and cut a section out of it to repair the area on mine that was damaged.
I drilled two holes and then used my jig saw to cut out the section that I wanted to use.
I removed the insert by drilling the heads off the pop rivets.
DO NOT drill all the way through the rivet.
Drill just deep enough to remove the head and then push the rest of the rivet through to remove it completely.
If you don't have an extra air box laying around you can always get some high density plastic and follow the same procedure other then you will have to drill some extra holes.

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I then sanded all the edges to remove the rough spots and I sanded all the surfaces that would be bonding to the air box.

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CLEAN, CLEAN, CLEAN! At this point, why not? You won't have a better opportunity then this.

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I really want to be sure that the patch piece and the box have a good opportunity to bond.

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Clean some more! Get it clean.
The final patch piece is checked for fitment and then cleaned again.

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Next apply a heavy amount of Permatex Ultra Black Hi-Temp RTV Silicone and gasket maker.

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Here's a note on Rivets.
When riveting plastic I always use a washer to give a wide displacement of pressure on the inside area.
This will help prevent the rivet from pulling through again.

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Push the rivet through the hole.

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Now, place a washer on the other side of the rivet.

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Attach the rivet gun and squeeze until the rod breaks off in the rivet gun.

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Perfect!
Now, put as many rivets in your you patch piece as required to hold it firmly in place.

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Let the Permatex dry overnight.
Then CLEAN IT SOME MORE!

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All done.
Any questions or suggestions?
Feel free to post or send me a PM
Thanks!
SB
If bikes are for kids I'll never grow up.

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