I have removed and reinstalled the fairing on my ultra a few times while installing my ARC mini amp and i seemed to have stripped one of the brass fittings that the screw goes into on the inside of the fairing. Anybody have any words of wisdom as how to remove and re-install them?

 

I had to replace one recently that I had stripped (most common problem is that they pull loose from the fairing). I had to, very carefully, drill out the existing brass insert and then tap new threads for the threaded replacement. Nerve wracking trying not to go too far!

 

The original inserts are knurled on the outside and pressed in the fairing. I imagine that it is spinning when you tighten the screw in it. You can try one of two things. Take a longer screw and thread it into the insert and try jacking it out or grabbing the screw or insert and pulling it out.

The replacement inserts are #16585-96. They are threaded on the outside and are slotted on one end.This is not a screwdriver slot. The slotted end goes in first. It is made to cut its own thread as it is being screwed in. This is done by threading a screw into the insert and driving it into the fairing using the screw,

 

I tried telling the parts guy at a local dealership this and he argued with me. Oh well. FWIW, I have had better luck with them by tapping threads first.

 

Nothing wrong with being cautious. As the saying goes, "The end justifies the means".

For the record, the tap size is 3/8-16.

 

you need to talk to the senior service guy. Parts guys never let you know their limited skills. Better yet get yourself a service manual. Then you can do like I do, just point it out to them. A good wrench is hard to find these days.

 

mine kept pulling out.... so i heated them up with a hair dryer and they came right out. put a little epoxy on them and put them back in. haven't had a problem since.

 

I have an '09 Ultra and had the same problem. I went to Home Depot and got a 1/4x20 tap and it only took two passes to get it cleaned up. Worked like a charm for me. I know someone on here said it was a 3/8x16 tap but on my '09 it was a 1/4x20 tap.

 

That was me. I should have been more specific.

The replacement inserts are #16585-96. They are threaded on the outside and are slotted on one end. For the record, the tap size is 3/8-16. The internal thread is a 1/4-20