Tour Pak Install Problem
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Joined: Mar 2008
Posts: 87
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From: Jefferson, MD
Tour Pak Install Problem
"Love" this...
I was just installing the docking hardware last night so I could add a removable Tour-pak to my "new" '05 RK Custom...should have only taken a few minutes...even my greyhounds could put it on right?!!...wrong...
As soon as I looked at thetwo "bolts" just above the rear mounting bracket...I realized right away I was probably going to have issues...the so called "bolts" Harley oddly usedare perfectlysmooth and round AND it's taken off by either an Allen wrench ortorx inserts and a socket wrench...in short, I realized that if they were even slightly tighter than they should be they'd round out quickly...
Sure enough...even with TLC...they rounded out...and didn'tbudge...now...that's an issue...how do you get them out??...I went to the hardware store and they suggested an "easy-out" bit...didn't work...actually made it worse...I'm now looking into a set of bolt extractors...
Overall, why would the bolts be so incredibly over-tightened? Second, why would Harley put this type of "bolt" on the bike? I notice in the service manual that there are hex nuts in the picture instead..that would have been MUCH better if a bolt needed more force to remove...
If the bolt extractor doesn't work...it's off to the dealer...[:@]
[IMG]local://upfiles/54656/60B9DC88A7394CEA969F934B158224C5.jpg[/IMG]
I was just installing the docking hardware last night so I could add a removable Tour-pak to my "new" '05 RK Custom...should have only taken a few minutes...even my greyhounds could put it on right?!!...wrong...
As soon as I looked at thetwo "bolts" just above the rear mounting bracket...I realized right away I was probably going to have issues...the so called "bolts" Harley oddly usedare perfectlysmooth and round AND it's taken off by either an Allen wrench ortorx inserts and a socket wrench...in short, I realized that if they were even slightly tighter than they should be they'd round out quickly...
Sure enough...even with TLC...they rounded out...and didn'tbudge...now...that's an issue...how do you get them out??...I went to the hardware store and they suggested an "easy-out" bit...didn't work...actually made it worse...I'm now looking into a set of bolt extractors...
Overall, why would the bolts be so incredibly over-tightened? Second, why would Harley put this type of "bolt" on the bike? I notice in the service manual that there are hex nuts in the picture instead..that would have been MUCH better if a bolt needed more force to remove...
If the bolt extractor doesn't work...it's off to the dealer...[:@]
[IMG]local://upfiles/54656/60B9DC88A7394CEA969F934B158224C5.jpg[/IMG]
Tourer
Joined: Aug 2007
Posts: 472
Likes: 1
From: NE CT.
RE: Tour Pak Install Problem
Torx or torx plus? Got to watch the difference.
http://www.wiha.com/index.php/englan...schraubprofile
Ratkiller
http://www.wiha.com/index.php/englan...schraubprofile
Ratkiller
Extreme HDF Member
Joined: Sep 2005
Posts: 11,615
Likes: 50
From: Baton Rouge, LA
RE: Tour Pak Install Problem
ORIGINAL: tenacean
"Love" this...
I was just installing the docking hardware last night so I could add a removable Tour-pak to my "new" '05 RK Custom...should have only taken a few minutes...even my greyhounds could put it on right?!!....
"Love" this...
I was just installing the docking hardware last night so I could add a removable Tour-pak to my "new" '05 RK Custom...should have only taken a few minutes...even my greyhounds could put it on right?!!....
Are you doing the front too? If so, the stripped-bolt problem is only the beginning. Wait 'til you remove the bolts in the vertical support and the three layers all shift out of place. Then, prepare for the cage nuts to fall into the support, and the contortions you'll need to perform to hold them in place.
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Extreme HDF Member
Joined: Sep 2005
Posts: 11,615
Likes: 50
From: Baton Rouge, LA
RE: Tour Pak Install Problem
ORIGINAL: Ratkiller
Torx or torx plus? Got to watch the difference.
http://www.wiha.com/index.php/englan...schraubprofile
Ratkiller
Torx or torx plus? Got to watch the difference.
http://www.wiha.com/index.php/englan...schraubprofile
Ratkiller
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Road Warrior
Joined: Mar 2007
Posts: 1,396
Likes: 146
From:
RE: Tour Pak Install Problem
ORIGINAL: tenacean
"Love" this...
I was just installing the docking hardware last night so I could add a removable Tour-pak to my "new" '05 RK Custom...should have only taken a few minutes...even my greyhounds could put it on right?!!...wrong...
As soon as I looked at thetwo "bolts" just above the rear mounting bracket...I realized right away I was probably going to have issues...the so called "bolts" Harley oddly usedare perfectlysmooth and round AND it's taken off by either an Allen wrench ortorx inserts and a socket wrench...in short, I realized that if they were even slightly tighter than they should be they'd round out quickly...
Sure enough...even with TLC...they rounded out...and didn'tbudge...now...that's an issue...how do you get them out??...I went to the hardware store and they suggested an "easy-out" bit...didn't work...actually made it worse...I'm now looking into a set of bolt extractors...
Overall, why would the bolts be so incredibly over-tightened? Second, why would Harley put this type of "bolt" on the bike? I notice in the service manual that there are hex nuts in the picture instead..that would have been MUCH better if a bolt needed more force to remove...
If the bolt extractor doesn't work...it's off to the dealer...[:@]
[IMG]local://upfiles/54656/60B9DC88A7394CEA969F934B158224C5.jpg[/IMG]
"Love" this...
I was just installing the docking hardware last night so I could add a removable Tour-pak to my "new" '05 RK Custom...should have only taken a few minutes...even my greyhounds could put it on right?!!...wrong...
As soon as I looked at thetwo "bolts" just above the rear mounting bracket...I realized right away I was probably going to have issues...the so called "bolts" Harley oddly usedare perfectlysmooth and round AND it's taken off by either an Allen wrench ortorx inserts and a socket wrench...in short, I realized that if they were even slightly tighter than they should be they'd round out quickly...
Sure enough...even with TLC...they rounded out...and didn'tbudge...now...that's an issue...how do you get them out??...I went to the hardware store and they suggested an "easy-out" bit...didn't work...actually made it worse...I'm now looking into a set of bolt extractors...
Overall, why would the bolts be so incredibly over-tightened? Second, why would Harley put this type of "bolt" on the bike? I notice in the service manual that there are hex nuts in the picture instead..that would have been MUCH better if a bolt needed more force to remove...
If the bolt extractor doesn't work...it's off to the dealer...[:@]
[IMG]local://upfiles/54656/60B9DC88A7394CEA969F934B158224C5.jpg[/IMG]
I worked as a Machinist/Tool and Die Maker for 42 years, here's a trick. When a hex socket or torx is rounded out, place a ball bearing or a rounded punch over thehead of the bolt. Hit it hard, support the back side if necessary, this will swage material back into the socket and you will have a firm grip again. If it has locktite, heat it with a propane torchbefore twisting onit. That will usually get it out. DO NOT reinstall that bolt again, discard it and replace it with a new one.
Drilling and easy outs are a last resort and will work if you can drill straight. The drill should self center into the wallowed out socket. Again a little heat before twisting with locktite.
Tourer
Joined: Sep 2006
Posts: 314
Likes: 0
From:
RE: Tour Pak Install Problem
I just installed the docking kit on my '08 FLHTC - those bolts have SAE Allen heads - I used a mechanics grade allen socket w/ratchet handle - they came out no problem. Don't use an allen key.