Bonneville America Forums Forums Technical Forums General Tech Airbox Cover/Pillon bolt thread

I was storing the bike for the winter and was trying to take the battery out. It seems the bottom bolt of the fake airbox cover is stripped. I can't remove the bolt so that the chrome cover won't lift off. I was able to detach the box, but now I need to replace the plastic part, and drill out the bolt. Anyone have a spare?

I also must have stripped the bolt holding the rear pillon when I installed the seat last summer. Would anyone happen to know the thread size?

Cheers.

Charles
getting ready for the airbox mod and the new carb jets

I have the original bolts for those covers. Make sure the nut inside is still seated in the plastic. It may not be stripped and if you can get behind it you may be able to save the day.
As for the pillion bolt, I believe it's a 6 x 1.0. Mine "stripped out" once and I was able to re-tap the hole and go again. The next time I took it apart it seemed too shaky to try again so I threaded a bolt up thru from the bottom and put a chrome acorn nut on the top side.

Grump,

I got the cover off, but I can't remove the bolt that holds the chrome trim piece off the plastic cover. There is a tube that the bolt goes into, is there a nut inside that tube? There is no way to get at it unless I cut the tube open, or if you know a better way....

Yes the bolt is a 6x10. I went to HD and saw matched it. Thanks.

Charles

I recently had my airbox out and compared it to another stock airbox (bought to modify). I discovered the fastener anchors, which screw into the plastic airbox were all stripped, in fact some were just gone! I ended up going back to the stock box, so I used JB Weld to anchor the fastener inserts, which seemed to work well. The small bolts that hold on the cheese grater are M5 bolts, fine thread. I've been looking for some chrome bolts to replace those black ones, but haven't found them in that size yet. I would not use any thread locker (I had used Blue Loctite) on those bolts, the anchors won't hold to that pressure when removing.
Hope that makes sense.

It's been awhile since I had those covers off, but I believe there is a nut insert at the bottom of that tube.
One thing you could try is to use an electric screwdriver or a drill to turn the screw while prying slightly between the chrome and the plastic. The speed and slight pressure may be enough to get the screw loose. Blip the trigger a few times....