Today i took my windshield off my 09 ultra as well as the fairing.when i was reassemling the windshield screw broke off the brass insert that's in the plastic fairing.it has about three threads left in it.i tried a longer bolt and some vice grips to remove it so i can epoxy a new one in but i can't get it out.
Until i return from sturgis i just went with a longer bolt so i can reach the threads but what are some suggestions for getting it out without cracking the **** outta the inner fairing

 

Have you tried using a screw extractor to get the old one out or is the insert broken?

 

Use one of those reverse thread extractor things (I'm very mechanical), that's what I did. Then replace the insert, HD has them for about $3. The split end goes in first (facing the rear of the bike), just start the screw into the insert then put it in the hole and use the screw to seat it in there. You don't need any glue or anything, but some people prefer to make sure and use some anyway.

 

I believe Harley makes a repair kit for just this same problem..

 

center punch and a left handed drill bit works if not real tight..

 

Insert is broken.only about 1/4" is in there down deep.
Are yins saying that the insert is also threaded?

 

Am I wrong in thinking it is the actual brass insert that broke? And not the bolt?

Toby

 

Jack it out, get a 1/4" 20 bolt with about an inch of threads. Screw a 1/4 20 nut on it all the way to the head of the bolt. Screw the bolt into whats left of the insert.

When the bolt bottoms out run the nut down the bolt till it touches the fairing. Now hold the nut with a 7/16 wrench and continue tightening the bolt, the bolt will not penetrate any deeper and the knurled insert will begin to back out of the hole. Bout the time it gets close to the nut it will probably pull out.

Replace knurled old style insert with new threaded insert

 

09 is probably the older style which are knurled on the outside.

You have the other piece, do you see any threads?

 

Jaw the other peice is gone.i am gonna jack it out when i get back from trip.
Thanks