ST1300 Air Cleaner Housing stripped screw hole repair

W0QNX

W0QNX

Blacksheep Tribal Member
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Pensacola, FL. USA
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06/ST1300 19/R1250RT
ST1300 Air Cleaner Housing stripped screw hole repair. Air filter housing.

I've had the airbox lid off enough times that the screw holes around the plastic air filter housing (air box bottom) have stripped out. I want to keep the air filter box closed up tight so the air filter will work as intended, air pass through the air filter not the air box lid to housing joint.

The stock housing has the black screw pictured below from Honda, SCREW, TAPPING (5X20) 93903-25480. The holes are worn too big so I simply installed a larger screw that threads in and actually passes through the hole bottom and out of the plastic box downwards.

I have good stainless steel screws available here locally so I used SS screws but I'm sure regular black phosphate coated or zinc plated will work as well. The new screws are #12 in size by 1.25" long panhead screws. A #12 screw has a nominal diameter of .216". I did clearance the plastic housing cover (THE COVER NOT THE BOTTOM) with a 7/32" (.2187") drill bit so the screws don't grab into the lid at all while being installed. I replaced 4 loose screw today with the larger SS screws.

It's pretty easy to do, clearance the lid holes if needed and use a hand screw driver to install the new screw down through the air filter base housing. I now have a good and tight appearing seal all around the air filter housing!

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Great post !!

I've done a similar fix. And I agree, switch to stainless for the screws / bolts. The advantages more than offset the cost.
 
My ST also had one or two larger SS screws sealing the airbox.
 
If the holes are worn just enough that the original screw no longer holds, you can get self-tapping screws from Yamaha that are just slightly larger in diameter than the original Honda screws. They fit in perfectly and hold well and look the same.
Yamaha P/N 90160-05013-00.
 
Andrew Shadow said:
If the holes are worn just enough that the original screw no longer holds, you can get self-tapping screws from Yamaha that are just slightly larger in diameter than the original Honda screws. They fit in perfectly and hold well and look the same.
Yamaha P/N 90160-05013-00.
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At $5.76 a piece. I paid 21 cents each for the SS screws.
 
Willsmotorcycle said:
You also had to pull the tank and drill the holes, if it took an hour, you're saying your time is only worth $22.20 an hour. If it took two hours?
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I don't understand your reasoning.

Does your air filter install itself?

With expensive or cheap screws I still have to change the air filter myself. Feel free to buy the more expensive screws if you want.

My time is free of charge to me and I waste a lot of it with the bike.
 
W0QNX said:
At $5.76 a piece. I paid 21 cents each for the SS screws.
Click to expand...
You are correct that it is not the cheapest option, and I was aware of that when I wrote it. Just provided the information as another option for the benefit of anyone who might be looking for a screw known to fit and is easily available. Their choice how much they wish to spend.
 
To avoid wearing those holes out...

When reinstalling the screws, place them in the hole, very light pressure on the screwdriver (the weight of the driver will do, just enough to keep it engaged with the screw head) and turn the screw backwards. You will feel it drop into place as the threads engage. Once it drops, you can turn it clockwise to tighten, without the screw trying to cut new threads in the plastic.

This is also true for screws into metal - helps prevent crossthreading.
 
I had one of the holes already stripped out when I went in and removed the air box the first time. I just used a regular #8 coarse wood screw the appropriate length and it works fine.

Cost was "free" because my father had given me a few boxes of screws he had and said he wasn't going to use them. :)
 
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