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[Mr D]

I was Re-installing the outer fairing on the CUSE last night and low and behold tightening the last inner torx bolt next to the right speaker and over tightened and pulled the bolt head through! Looking for some experience on this one for a fix?

Thanks in advance riders...

Tom

[Cvostu]

HD does offer a repair insert that would thread into the same place where the stock one pulled out from. Once it is screwed in properly and at the right depth, the brass posts break off, Then it leaves you with a 1/4-20 thread to attach your fairing to..  They are pretty cheap.  Get some extras..  won't hurt to keep the handy.

[Mr D]

HD does offer a repair insert that would thread into the same place where the stock one pulled out from. Once it is screwed in properly and at the right depth, the brass posts break off, Then it leaves you with a 1/4-20 thread to attach your fairing to..  They are pretty cheap.  Get some extras..  won't hurt to keep the handy.

I'll call the dealer first thing in da' am.
Thanks Stu 

[Cvostu]

Anytime...  I've pulled a few in my day... It is so easy to do,,   Gotta be really careful with those.

[Twolanerider]

If it's pulled completely through you'll have to build it back up.  There are ABS patch kits of all different kinds out there.  It's likely some here will have some suggestions.  Personally I prefer plastic welding for this kind of repair.  You can do it cheap to as the "welder" doesn't have to be very expensive.

Here's the welding "rod":

http://www.harborfreight.com/50-piece-plastic-welding-rods-41602.html

The package has several different types.  You'd use the ones specifically for ABS.


Here's a welder:

http://www.harborfreight.com/welding/plastic-welders/plastic-welding-kit-with-air-motor-and-temperature-adjustment-96712.html

That one has it's own air supply (off a big compressor that can be a chore to get regulated down where you need it) and adjustable temp.  For something you'll not use often (hopefully not ever again) it's not a bad little tool even if it is from Harbor Freight.  They've got others that are cheaper also.

I've done this (on other ABS parts not parts of the bikes) and if you're careful with the temps painted areas next to what you're building up can be mostly unblemished.  Get some yellow touch up paint and give it a try.  Inner fairings are expensive.

[Twolanerider]

I'll call the dealer first thing in da' am.
Thanks Stu 

Sorry, I misunderstood and thought you'd pulled one of the bolt heads through the inner fairing rather than pulling out one of the inserts.

[Mr D]

Sorry, I misunderstood and thought you'd pulled one of the bolt heads through the inner fairing rather than pulling out one of the inserts.

Don<

As i was tightening it up the outer fairing popped forword, I assumed (bad idea) that the torx head popped through the glass  I need to look closer, As stu mentioned the brass insert may be just stripped. Is it likely for the bolt to pull through the glass? not like i was torque n' a head bolt, Just firmly snug.

thanks for the input as well 

[Twolanerider]

Don<

As i was tightening it up the outer fairing popped forword, I assumed (bad idea) that the torx head popped through the glass  I need to look closer, As stu mentioned the brass insert may be just stripped. Is it likely for the bolt to pull through the glass? not like i was torque n' a head bolt, Just firmly snug.

thanks for the input as well 

Those are ABS plastic not fiberglass.  It has some give to it.  Have seen both problems; pulled inserts and screws pulled through those holes on the side.  Since there is actually surface to surface contact between the inner and outer where those screws tighten up (if it's all aligned correctly) have only seen those screws pulled through an inner fairing rarely though.  Hopefully you've just popped an insert.  That's a much easier, cheaper and quicker fix.  Good luck.