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Discussion Starter #1
4 of the 6 phillips head pan screws (Honda part # 91508-MM5-000) mounted at the base of the air funnels in my 2000 929's airbox are stripped. I'm sure I made the heads worse when trying to remove them (they were extremely tight due to previous work done by a shop years ago). Any advice on how to get them out?? I've heard about drilling out, but have never done that before. Thanks in advance.
 

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When you say stripped, do you mean heads sheared off, or do you mean can no longer get purchase on the head as the "cross" has gone?

If the latter, could try getting a Dremel in to cut a new groove (if you can reach)....then you can use a screwdriver.....

Pics may help others to provide alternate suggestions....
 

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Discussion Starter #3
The head is still intact, but the cross is stripped. I indicated in red in the attached pic what I'm referring to (upper right side showing the air funnels and screws/locations).
 

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That certainly looks tricky......can't imagine how you will cut another groove from in there...

Hopefully some of the other members will have some ideas.

Between now and then, try some WD40, and perhaps put a screwdriver in the slot and tap it back with a hammer.... Might just break the lock on the threads...

If the air funnels are easily replaceable, there is always plan z.......
 

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I would probably get a removal tool such as this, which "supposed" to cut into the damaged area and break it loose. It also allows for you to use a 1/4" extension attached to a ratchet and make a minimal mess inside the airbox. Trying to drill those out would pose a huge risk in getting debris in the intake track. Drilling is usually a last resort, worst case scenario.

 

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I'll have to get some of those..good job it's christmas... Perhaps St Nick will visit (unbeknownst to the wifey).....:eek:
 

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I had the same issue on my 929. Ended up snapping the trumpets off. that then let me get some pliers onto them so i could remove the box. Ended up buying a new airbag off eBay with non stripped screws :)
 

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I also have this same issue literally every time I take the air box apart. Last time I ended up breaking the stack that had the stripped screw and used pliers like the last guy said. I'm leary of drilling and creating soo much metal that deep in the intake tract. I'm still looking for Allen head replacements that have the same shoulder those bolts have. I'll let you know when I'm successful. I absolutely hate Phillips screws on Japanese bikes, as with carburetors the heads seem to be made of pot metal...
 

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I also have this same issue literally every time I take the air box apart. Last time I ended up breaking the stack that had the stripped screw and used pliers like the last guy said. I'm leary of drilling and creating soo much metal that deep in the intake tract. I'm still looking for Allen head replacements that have the same shoulder those bolts have. I'll let you know when I'm successful. I absolutely hate Phillips screws on Japanese bikes, as with carburetors the heads seem to be made of pot metal...
What's the issue with the "shoulder".....

Is it something that can be "turned" from normal Allen heads?

As an example of the suggestion - I "adapted" the nuts and some button head Allen bolts so I could mount a vfr800 wheel on a vfr750 SSSA without machining slots into the wheel.
 

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What's the issue with the "shoulder".....

Is it something that can be "turned" from normal Allen heads?

As an example of the suggestion - I "adapted" the nuts and some button head Allen bolts so I could mount a vfr800 wheel on a vfr750 SSSA without machining slots into the wheel.
See here for nut - shoulder turned in so would fit into the disc carrier - the nut is now circa half as deep on the back of the plate, but full depth at threads and through the carrier...
 

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Discussion Starter #14 (Edited)
Well, like the couple of others in this thread, I wound up snapping the stacks off, then used pliers to remove the stripped screws. My airbox was not damaged at all. I ordered a good used set off ebay, I should have them soon. I did try an extractor tool first, but no luck.
 
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