It was bound to happen. I've removed and installed the outer fairing so many times over the past few years that something was bound to break or crack. The plastic around one of the bottom outer fairing screw holes is cracking and the threaded insert is shot. The other bottom thread insert probably needs to be replaced as well. I had to use a tap to clean up the threads, so at least one screw will work for now.

Just to clarify, I am talking about the very bottom two screws on the outer fairing - not the windshield screws and not the middle screws near the mirrors.

Is there a way I can repair the plastic and replace the threaded insert? There is no part listed for this in the parts catalog?

If I replace the outer fairing it with a prepainted part it will cost $344. It looks like I can use my existing headlight on the new shell. Obviously I'd rather not spend the cash.

 

HD sells a replacement insert that threads in, it's much better than the original design. It will work as long as you can get the 2 OEM inserts out (I had to VERY CAREFULLY drill mine out on my previous bike) and as long as the surrounding plastic is stable. For that I would try JB Weld, the greatest invention mankind has ever known.

 

Yep install new inserts using the JB Weld. Worked great for me.

 

go to harbor freight and get you a drill bit stop. it's a little collar with a set screw that is bought per bit size and that way you cant accidently drill through. If they don't have them I would try like granger. or here a set for 11 bucks. well worth the investment IMO.

http://www.amazon.com/Drill-Bit-Stop.../dp/B0039ZEZNG

 

I do alot of plastic repair in my bodyshop and found this 2-part 5 minute epoxy called "Plastic Weld". I like it better than JB Weld because it sets up in 5. I get it at our local NAPA

 

I have been using the 15 minute JB Weld. It gives me just the right amount of time to work with it. It is also heat resistant if I need it for other repairs. The regular JB Weld doesn't tolerate heat as well.

 

I finally got around to fixing the bottom screw inserts and the cracked faring material. I drilled out the old threaded inserts and installed the new inserts. I used the JB Weld to fill in the damaged fairing material and let it set for a day. Everything came out reasonably well. Thanks for the tip. This saved me over $300!