Issues with installation crash bars
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6th Gear
Joined: Jul 2021
Posts: 11
Likes: 12
From: IL
Issues with installation crash bars
This has been the unnecessarily difficult project from hell. First, battled a stripped torx bolt when removing upper bolts. I finally got it out and celebrated bc the rest would surely be a breeze, right? I mean it's just 4 new bolts after all. Wrong. The top two bolts only go in halfway and one of them ends up crooked every time toward the end of trying to thread it in. The bottom bolts go in just fine. So my question is. Do you think they sent me the wrong size bolts or do I just need to tap the holes to try to reset the threads? Cuz like I said they go about halfway in and just stop. The bike is 10 years old so maybe there's buildup in there? No idea but beyond frustrated going on a week now of a project that should have taken 20 mins. Any advice would be appreciated!
Seasoned HDF Member
Joined: Dec 2009
Posts: 17,684
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From: Niagara, Ontario, Canada
Not sure what size they are, but running a tap thru wouldn't hurt, but sounds with your luck so far, you may break it in there, lol. Are you sure you have the right threads on the bolts ?
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6th Gear
Joined: Jul 2021
Posts: 11
Likes: 12
From: IL
They're the bolts sent with the kit from Harley and they appear to be the same size/thread as the ones that were removed. I feel like my only option is to try a tap at this point. 🤷♀️ Maybe I'll grab a couple smaller bolts to try just in case. I have a feeling there's rust up inside. Of course. Lol.
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6th Gear
Joined: Jul 2021
Posts: 11
Likes: 12
From: IL
But not sure if bolt is sae or metric??
Road Warrior
Joined: May 2017
Posts: 1,966
Likes: 1,582
From: Scottish Highlands.
H-D use a patch of thread locking compound on their fasteners which is similar to "Loctite 243" on their stock hardware, after removing the stock bolts there is still some of the thread locking compound left in the threads, it's advisable to run a 3/8-16 tap down the threads to clean them out and redress them before inserting a new bolt. If you don't clean out the threads the new bolt will get stuck in the thread locker and try to compress it down into the bottom of the threads so the new bolt will bottom out before it's fully screwed home.
After cleaning out the threads, it the new bolts don't have a lock patch on them just smear a little Loctite 243 on the threads and torque them to 25 to 35 ft-lbs or 33.9 to 47.5 Nm.
After cleaning out the threads, it the new bolts don't have a lock patch on them just smear a little Loctite 243 on the threads and torque them to 25 to 35 ft-lbs or 33.9 to 47.5 Nm.
Thread Starter
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6th Gear
Joined: Jul 2021
Posts: 11
Likes: 12
From: IL
H-D use a patch of thread locking compound on their fasteners which is similar to "Loctite 243" on their stock hardware, after removing the stock bolts there is still some of the thread locking compound left in the threads, it's advisable to run a 3/8-16 tap down the threads to clean them out and redress them before inserting a new bolt. If you don't clean out the threads the new bolt will get stuck in the thread locker and try to compress it down into the bottom of the threads so the new bolt will bottom out before it's fully screwed home.
After cleaning out the threads, it the new bolts don't have a lock patch on them just smear a little Loctite 243 on the threads and torque them to 25 to 35 ft-lbs or 33.9 to 47.5 Nm.
After cleaning out the threads, it the new bolts don't have a lock patch on them just smear a little Loctite 243 on the threads and torque them to 25 to 35 ft-lbs or 33.9 to 47.5 Nm.
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Road Warrior
Joined: May 2017
Posts: 1,966
Likes: 1,582
From: Scottish Highlands.
If I remember correctly the stock fasteners at the top fixing points for the crash bars are 3/8-16 x 1-1/2" long toex socket button heads.
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Seasoned HDF Member
Joined: Sep 2017
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From: England
If you are going to run a tap through an already tapped hole then get a thread cleaning tap or chaser tap.
I have fitted a HD engine guard. The engine front link had torx screws but they didn't have a lock patch on them. The top bolts being slightly longer to replace the ones that were already there. It fitted perfectly, something I have found with all HD stuff.
I have fitted a HD engine guard. The engine front link had torx screws but they didn't have a lock patch on them. The top bolts being slightly longer to replace the ones that were already there. It fitted perfectly, something I have found with all HD stuff.
Last edited by Andy from Sandy; Apr 25, 2022 at 01:00 PM.
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