Help! Pulled Threaded Insert on Rushmore Inner Fairing
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Road Warrior
Joined: Feb 2016
Posts: 1,354
Likes: 399
From: Vancouver, BC
Help! Pulled Threaded Insert on Rushmore Inner Fairing
Hi, while removing the speaker pod on my bike one of the 3 metal threaded inserts that hold the pod to the plastic inner fairing pulled out (I suspect the hex bolt was over-torqued during installation. What's the best way to fix this? I'm thinking a small amount 2 part epoxy but thought I'd check here first.
(P.S. why would Harley have made it SO HARD to remove those other bolts that hold the pod to the radio tray? Why? It's just evil)
(P.S. why would Harley have made it SO HARD to remove those other bolts that hold the pod to the radio tray? Why? It's just evil)
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Road Warrior
Joined: Feb 2016
Posts: 1,354
Likes: 399
From: Vancouver, BC
On your advice I went by the dealer and they sold me a metal threaded insert repair which is an insert threaded on the outside to screw into the stripped hole in the inner faring and accepts the original hex bolt. The parts catalog does not show it but it's the same one used to repair the inserts holding the windscreen in place. In case anyone else needs it the p/n is 16585-96. Thanks for the info.
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Road Warrior
Joined: Feb 2016
Posts: 1,354
Likes: 399
From: Vancouver, BC
just a quick follow up and note of caution. The repair insert might be of too large a diameter to fit in the existing hole. In my case, I noticed the wall of the plastic surrounding the hole was split as I tried to screw in the repair insert. It very well may have been split when the bolt was originally installed or when I tried to unscrew it. I would still recommend giving it a try but luckily, as it turns out, I'm not putting the pods back in and so I don't use the affected bolt insert anyway.
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Road Warrior
Joined: Feb 2016
Posts: 1,354
Likes: 399
From: Vancouver, BC
Well, I checked with HD customer support to see if there was a proper repair kit for this. I thought there might not be as there was not one listed in the parts catalog while there was for the (almost) identical part used to hold the windscreen. They confirmed there is no repair kit and the inner fairing must be replaced. Lol. Thousands (if done by the dealer) to fix a two cent part! Ive asked if they will recommend a glue or epoxy that is safe to use and barring that, the type of plastic used so that I can find the proper material myself. Im confident that if I repair the crack and build up a little more material around the hole I can successful repair this using the part I mentioned earlier Ill report back if there is any news
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