I removed my upper fairing to install a garage door remote opener. When I was reinstalling the fairing, one of the bolts (the bottom, left, behind the fork tube), somehow got cross threaded, and in attempting to remove it, I managed to strip the torx drive recess in the screw head. Now the torx bit is just turning, without driving the screw (the screw is half way in). Anybody has any idea how I can remove this screw? The location is pretty tight, so no other tools (like a vise grip) can be used. Not even a Dremel tool can fit in there, so that I can cut a straight slot in the screw head. Argh....
Your help would be greatly appreciated.

 

Try lightly tapping in the next size bigger torx on an extension. Can't possibly be very tight...right?

 

Get what they call an easy out ,drive it in the head and try to turn out. When you get it out chase the threads with a 1/4 x 20 tap. That is what size it is and get a new bolt and put it in. Or maybe a set of neddle nose vice grips and turn it out.

 

Once you get the screw out, if you also stripped the threads out of the inner fairing, HD sells brass bushings to install into the fairing. Don't ask me how I know.

 

I,ve replaced the three uppers with the new style insert which is threaded on the outside as well as the inside. This insert replaces the knurled insert that keeps backing out.

 

Unfortunately, you're going to have to get that bolt out and replace the insert with the repair type that threads in (P/N 16585-06). Install it with epoxy too. With the bike on the jiffy stand turn the bars to the side to gain better access to the culprit. Then do what u can to get it out. The insert will be turning in the fairing, so more than likely you'll have to pull on the bolt with visegrips, while someone pulls on the fairing at that location, then separate the bolt from the damaged sert.
good luck
copter

 

Cutting wheel in a Dremel Motor tool.

 

if you can get to it with a drill use a reverse drill bit, it might back it out if not you will have a hole to use a easy out to back out screw

 

Try a "broken screw remover" in a cordless drill. Craftsman, Irwin and a few other companies make them. It's basically a cutting head that works with the drill in reverse. A 1/4" quick disconnect extension in the drill will let you reach into that tight spot. Works really good on stripped torx.

 

ditto on the screw removers,they are a great solution for your problem. i have used them many times. if you do much wrenching they are a necessity.