Stupid Harley Torx Bolts
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Joined: Jun 2009
Posts: 67
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From: Andover, MN
Stupid Harley Torx Bolts
So I was in the process of moving my turn signals down to the front forks when disaster struck. The left side bolt came out, tough, but came out. The right side was a nightmare. I couldn't get it to budge, I tried everything....air wrench, liquid wrench, WD-40.....still nothing until eventually the torx stripped out.....I tried a few more ideas I had until the head snapped off the bolt. Now I was stuck with the remaining portion of the bolt still inside the clamp. I tried to drill it out.....which sort of worked....I didn't get the entire bolt out but I figured I could run a tap through it to re-thread it and then put a new bolt back in.....Ran the tap and everything seemed fine, except now the bolt threads don't want to catch the internal threads.....it thread for about 1/4" and then slips and won't tighten any further. What are my options at this point? I used a 3/8" tap which would acomadate the stock bolt size of 3/8"- 24 x 1 1/4". Should I just go and get a 1/2" tap and re-thread it bigger and use a bigger bolt? Any help is greatly appreciated.
Cruiser
Joined: Jul 2009
Posts: 127
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From: Plainfield, Illinois
You could use a larger tap and bolt if you have the space to do so; otherwise, you could use a helicoil kit and go back with a 3/8" bolt.
Run the bolts through a die first before installing them - this will save a lot of grief donw the road. I have found from previous dealings that when whoever chromes the bolts chromes the threads as well; running them through a die will make installation much easier and eliminate the issue you are having.
Run the bolts through a die first before installing them - this will save a lot of grief donw the road. I have found from previous dealings that when whoever chromes the bolts chromes the threads as well; running them through a die will make installation much easier and eliminate the issue you are having.
Road Warrior
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From: Blind Bay, BC
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Joined: Jun 2009
Posts: 67
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From: Andover, MN
It was the bolt for the clamp that goes around the front forks. there is one on each side....Many on here used this location to relocate their turn signals. Of course that was my intention as well. Screw extractors were not an option because the bolt appeared to be stuck in there. What I ended up doing was spending several hours drilling it out, re tapping it and using a helicoil. It wasn't easy but I finally have it back together. What a Pain in a**!
