Screws stuck in plastic

Kevin K said:

I'm trying to get the plastic air filter boxes apart on my '01 748S. Most of the screws that hold the two pieces together won't budge. Before I stip one of them, can anyone recommend a way to get those screws out? Heat? I've tried WD-40 to no avail. I'd rather not have to use my extractor, but will if that's the only way.

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Are these screws that go into brass inserts in the back plastic piece? If so, I'd suggest drilling the head off - it's way too easy to crank them hard enough to break the plastic around the brass insert once you start forcing things. Once you've drilled the head off you've removed the clamping force so you can usually twist the remains out with your fingers, only occasionally do you need to grab it with pliers or vice grips...

big

just wondering, but if I'm understanding the part you're trying to deal with correctly, how come you're trying to take those out? from my experience, there should really be no reason for you to have to take those screws out... iirc anyways, I may just be having a brain fart...

bigiain - They appear to be sheet metal screws coupling the two plastic halves of the air filter boxes.

hiero - I'm trying to remove the air filter boxes to replace them with CF boxes the seller gave me with the bike. I tried a few gentle tugs on the boxes to try to pry them off of the air box, but when they didn't pop off, I thought I'd be careful and dismantle the filter boxes to see if there were other fasteners holding the filter boxes to the air box. If I don't need to dismantle the air filter box to remove it, can I just pop them off of the air box??

Thanks!

yeah, you shouldn't need to take those sheet metal looking screws out to remove those side ram air boxes. iirc, the last time I took those off a 748, I had removed the front fairing before i took the boxes out, I can't remember if that's entirely necessary, but I do remember there being a bolt at the front of each box that needs to be removed...

if you like, I can go out to the 748 sitting in my garage (not mine, but it's sitting with me at the moment) after work today and refresh my memory. ???

I had the front and both side fairings off and don't remember seeing any bolts on the boxes...just the screws. When I wiggled the boxes they didn't appear to be attached anywhere but to the air box. Do you think it just pops off? If you get a chance to look at the 748 you have without undue inconvenience I'd appreciate it, but I don't want to impose any more than I already have (well, at least not too much more )

Kevin K said:

I had the front and both side fairings off and don't remember seeing any bolts on the boxes...just the screws. When I wiggled the boxes they didn't appear to be attached anywhere but to the air box. Do you think it just pops off? If you get a chance to look at the 748 you have without undue inconvenience I'd appreciate it, but I don't want to impose any more than I already have (well, at least not too much more )

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no problem, there was definitely at least one bolt holding them on from what I remember, I'll check it out when i get home today

Ok, sorry for the late reply (I fell asleep after work )

but I think I've figured out what's going on, did you take the fuel tank off yet? I'm guessing you haven't.

If you take the tank off (open the seat latch, take the seat off the hinges and disconnect rear lights, remove the 5mm hex head bolt holding the tank on, pull back on the tank, then you should be able to rotate it 90 degrees so you can see the airbox underneath, remove the air filter if there's a full one there), where the side vents enter the airbox, you'll find two spring clips that hold the side vents in place.

You've already removed the front bolt as that's what partially holds the front fairing in place, so if you've removed the fairing, the spring clips should be the only things left to remove other than the signals.

Let me know if that helps any and if you get stuck again, just post up here [thumbsup]

Thanks hiero. Nope, didn't take the fuel tank off. I'll do that next to get at those clips.