Stripped fairing insert
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Tourer
Joined: Aug 2005
Posts: 491
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From: New York City Area
Stripped fairing insert
Has anyone who stripped the lower torx fairing screw removed the stripped insert and installed the factory replacement brass sleeve successfully without damaging the plastic mounting? How did you remove the old one the new one appears to have a scredriver slot to put it in? I took the fairing apart to put in the HogTunes Tweeter Pod a few times and I stripped the right lower Insert, I got the repair insert from the dealer and just am afraid to caus more damage trying to fix it? Thanks Bill
Grand HDF Member
Joined: Sep 2005
Posts: 4,890
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From: MA
Just a heads up, that slot is not a screw driver slot. The slotted end goes in 1st. It helps to cut its own thread. To do this, you thread a hex head bolt into the insert being careful not to extend the bolt out the other end. You may have to use a nut to lock the bolt in place. Drive the insert in by the hex head bolt using a socket wrench. The plastic is giving enough to allow this replacement procedure. The proper way to replace that kind of insert would be to tap the hole out with a 3/8-16 tap.
As for removing the old insert, again use a hex head bolt and screw it into the insert. Using a hair drier heat around the insert and pull the insert out by the head of the bolt. Do not use a heat gun as this will provide too much heat.
As for removing the old insert, again use a hex head bolt and screw it into the insert. Using a hair drier heat around the insert and pull the insert out by the head of the bolt. Do not use a heat gun as this will provide too much heat.
Seasoned HDF Member
Joined: Feb 2007
Posts: 10,602
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From: Bellevue, NE
You can try Soos' idea. I drilled mine out. Very carefully and progressively larger bits until it finally broke free and the last little fragment came out. Use tape on your drill bits so you know how deep is too deep.
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Tourer
Joined: Aug 2005
Posts: 491
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From: New York City Area
Fairing Stripped Insert
SooS thanks for the reply man I'm glad I didn't try to fix it I put it back together and the hex bolt only would tighten about half way so I took it out and used a washer so that at least the fairing Hex screw would be snug as the fairing was vibrating cause I couldn't tighten it so its OK for now till next weekend when I have the time to get to it man you are the "MAN" sounds like something I can do LOL about the slots I thought they were for a screwdriver blade, shoot that would have been funny if I tried it and had to go to the dealer to fix it!! Also thanks for letting me know about the hair dryer and not a heat gun, which I have in my tool box and may have been tempted to use!!Ill see like I said I may try it truth is the bike is going in next month for 10K and the dealer has to take off the fairing to replace the odometer reset button!
Stro1965 thanks for your tip sounds like that will work also, I really thank you both, Bill
Stro1965 thanks for your tip sounds like that will work also, I really thank you both, Bill
Last edited by daharleyrdr; Jul 26, 2009 at 05:17 PM.
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