One of the voltage regulator studs sheared off at the base on my 2005 Road King. The stud appears to be a press fitting into the frame. Has anyone had any experience in removing a boken stud and replacing it with another? It does not show up as part of the frame illustration in the parts manual (page 71); only the two holes are shown, nor does the stud appear as a part #. I half heartedly tried to punch it out and had no success. The bike is out of warranty (last August) so I am on my own here. Any suggestions would be appreciated.

 

Any ideas on this? Otherwise I have to take to the dealer to have it removed. HD won't cover it on warranty.

 

The easiest fix would be to drill it out and replace it with a bolt.

 

i agree, cause that's what the dealer will do.

 

That or try to punch it out from the bottom, if it's accessible.

 

I found the same thing on my bike recently, and it is still under warranty. They want to do a FRAME SWAP!! They said they cannot drill it out and replace with a bolt as a warranty action.

 

darrlym:

I called HD headquarters and they offered to cover it under warranty even thoughthe warrantyexpired last August but they wanted to charge me a $100 "out of warranty fee" which we agreed was probably pretty close to what it should cost to have the broken stud removed (That remains to be seen). Let me know if they actually replace your frame. I can't believe they would actually do that. I went to the local Harley dealer today and they referred me to a local tap and die company to whom they would send the bike out to if I left it with them. They did not recommend trying to drill it out.

 

I wonder why? Maybe 10 cents vs $100. You could also weld another stud on for about 10 -20 cents.(If you have access to a welder)

 

Remove both studs! Grind it down top and bottom with a Dremel and then knock out what's left with a punch. Then get you some of those spiked acorn nuts and make you something no one else has! (Until you post it pics!)

 

I just ended up in the same situation due to a broke torque wrench that caused me to tighten more than it was supposed to. How did you guys end up on this?