Tricky Problem
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Cruiser
Joined: Jul 2007
Posts: 159
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Tricky Problem
I want to replace the scratched engine guard (crash bar) on my '08 Ultra. The top center bolt that goes into the fork area comes out but the nut, that appears to have been spot welded in originally, is now loose. If I back the bolt all the way out, the nut will fall into the closed fork area and I can't use that bolt again.
 \\;
Someone suggested using a time-sert bolt like the ones used in stripped head bolts but I don't think that will work since the nut for the top engine guard bolt is at the end of a bored hole in the fork. It seems that a time-sert will have nothing to stop it from screwing all the way into the fork area, if I am making myself clear.
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Has anyone faced this dilemma before? What did you use to secure the top of the engine guard in place?
 \\;
Someone suggested using a time-sert bolt like the ones used in stripped head bolts but I don't think that will work since the nut for the top engine guard bolt is at the end of a bored hole in the fork. It seems that a time-sert will have nothing to stop it from screwing all the way into the fork area, if I am making myself clear.
 \\;
Has anyone faced this dilemma before? What did you use to secure the top of the engine guard in place?
Road Master
Joined: Feb 2006
Posts: 805
Likes: 0
RE: Tricky Problem
Can you get the bolt out far enough with out take it out to see it. \\; If so then go by a muffler shop and have them put a tac weld on it to hold it in place. \\; This will hold it long enough to get the crash bar off and put a good weld on it. I am not looking at my bike, but you should have just enough room in there to get a small tac to get the bar off. \\; If you are in the Dallas area you can shoot me a PM and come by and I will \\;try and do it for you.
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Jeff
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Jeff
Thread Starter
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Cruiser
Joined: Jul 2007
Posts: 159
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From:
RE: Tricky Problem
I looked real close and it appears that the top engine guard \\;nut is inside a closed in area where the frame members all converge in the fork area. If I could get to the nut, it would be easy to tac weld the nut back into place. It's a closed in box without any access from what I see. I don't know if there is an access to the nut from above if I remove the gas tank - that is a lot of work if it's a dead end. \\;
 \\;P.S.: I don't know where all these double back slashes are coming from. I'm not keying them.)
 \\;P.S.: I don't know where all these double back slashes are coming from. I'm not keying them.)
Road Master
Joined: Feb 2006
Posts: 805
Likes: 0
RE: Tricky Problem
I will take a look at my RG and RK when I get to the house and let you know if I can come up with something for you. \\; I am sure there has to be something that you can do.
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Jeff
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Jeff
Seasoned HDF Member
Joined: Jan 2007
Posts: 20,616
Likes: 4,440
From: anacoco, la
RE: Tricky Problem
the top nut on the engine guard is actually part of the guard itself. \\; at least it was on my road king (2007). \\; it was spot welded to the upper tab on the engine guard, so if you are replacing the whole guard, there should be no problem, short of not being able to get the old bolt off in the first place.
Road Master
Joined: Mar 2007
Posts: 973
Likes: 0
From: Mt Dora Florida
RE: Tricky Problem
It's under warranty! \\; Take it to the dealer and ask him what needs to be done!
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Road Master
Joined: Feb 2006
Posts: 805
Likes: 0
RE: Tricky Problem
I just looked at some old photos of the crash bar that I took off my RK and mine was a straight through bolt like TNBagger is talking about. \\; My RK is an 04 so maybe they changed it because of this problem.
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If it is under warrenty take it to the dealer and put it on them.
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http://i181.photobucket.com/albums/x...rash_Bar_1.jpg
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Jeff
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If it is under warrenty take it to the dealer and put it on them.
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http://i181.photobucket.com/albums/x...rash_Bar_1.jpg
 \\;
Jeff
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Tourer
Joined: Jun 2008
Posts: 275
Likes: 0
From: Southern MD
RE: Tricky Problem
From what i can remember from when i took mine off for powdercoat its open on the engine side. You may be able to put a bolt in the nut under the tank while the outside bolt is still in. Get it started take the crash bars off and leave the bolt under the tank in while you do your fix. Just repeat the steps backwards to reinstall.
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