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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Broken airbox mountings - How would you repair these?
Post Info TOPIC: Broken airbox mountings - How would you repair these?
BikerMat


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Broken airbox mountings - How would you repair these?
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Hey guys, Mat here

I have two broken mountings on my airbox, caused by a perished bump stop on the rear shock allowing the tire to grab the mudflap and rip the airbox downwards after what I presume was a totally sick jump (Thankyou previous owner).

2NH2axk.jpg

This is the top mounting. My plan was to heat the plastic and flatten it back down, then use adhesive to fill in the cracks. To attach it to the bike I'd like to use a nut attached to square washer (Or square nut), with another washer ontop to create a nut/washer - plastic - washer - bolt sandwhich. I think this should be strong enough.

0QpcGeU.jpg

This is the exhaust side, side mounting. I'd like to plastic weld to fill in the gap, and then use the same nut and washer sandwhich to mount it to the bike. The airbox is made of polypropylene though. Is PP easy to plastic weld with? Is plastic filler an option?

How would you guys repair these mountings, is there a better way?

Thanks, Mat.

 



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TTRfan


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Hi Matthew

Quite a frequent occurrence where the airbox hasn't been off for a while unfortunately cry

The easiest solution that saves mucking about with plastic welding etc is to push the old nuts back in and use big self tappers instead of the old bolts.

They will hold the box in place and shouldn't cause any air leaks as they self seal wink

Brian



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TTRfan


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Has anyone come up with a good solution to repairing/replacing the three captive nuts when they have rusted onto their bolts and break out of their "cages" in the airbox?

I know that it is possible to get a good fix by using long self tapping screws of a decent diameter but am looking for a more elegant solution if possible wink

Brian



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TTRfan


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Nobody came forward with a better solution so chunky self tappers is the way to go!

Having sold my TTR, I have quite a few spares that I had been keeping back that I can now sell. Quite why I have three spare airboxes I am not sure!

Anyways up, the captive bolts on one of them had been cut out so I thought it a good opportunity to take some photos and create a "how to" guide. But, to be honest, it was so easy, that it probably didn't deserve the time and attention no

It is a really good fix so here is the guide just in case it helps another owner biggrin

Brian

PS The airboxes along with a lot of other spares will be making their way into TTR Steve's shop very soon!



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mossproof


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I never saw the original thread! I would drill right through, run a bolt up from inside the airbox through a nut in the "captured nut socket" that holds it in place, and a nice stainless flanged nut to hold it all in place.

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TTRfan


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I think that would work Simon! I will check accessibility. No problem with the self tappers as you don't need to put your hands inside the airboxwink 



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JOHNYBOY


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ther is something called delta solution we use at work that would do it ill find out more tomorrow

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JOHNYBOY


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Found it on eBay. Delta Fast Black D350 - absolute brilliant!



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mossproof


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TTRfan wrote:

I think that would work Simon! I will check accessibility. No problem with the self tappers as you don't need to put your hands inside the airboxwink 

 Once the bolt is in place you don't need to touch it again - treat the protruding thread like a locating stud.

That stuff looks good John



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JOHNYBOY


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yes simon its good sets like hard plastic

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TTRfan


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I got a cracked airbox that I can use to test that system out on Simon. Will let you know how I get on wink



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TTRfan


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JOHNYBOY wrote:

Found it on eBay. Delta Fast Black D350 - absolute brilliant!

 Do you need to buy a special gun to use it John?



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JOHNYBOY


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yes to mix it together in the small nozzle but not too expensive

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