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Author Topic: Headlight bulb replacement Part 2  (Read 882 times)
Kong6778
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Posts: 21


« on: April 22, 2015, 08:19:31 AM »

On my 2001 IS I asked for your help on how to replace the headlight bulbs. I got many responses that were of a great help.....EXCEPT, upon trying to take off the speaker covers on the inside of the fairing, as I was instructed, none of the screws on either side would come off. I don't know if they are stripped or whatever they screw into behind the fairing is just spinning in place!!! HELP!!! What do I do now?? I'm not much of a mechanic but I'm not a dummy either, if someone could please explain to me what I need to do I sure would be eternally grateful. Thanks again.

                                                                    Kong 6778
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pancho
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Posts: 2113


Bonanza Arkansas


« Reply #1 on: April 22, 2015, 08:28:29 AM »

I don't have an interstate Kong, but I have seen many posts about the brass nuts in the fairing breaking loose from their mounting and the repair for that. Hold on, some of the Interstate guys will have some ideas for you.
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The most expensive things you will purchase, are those things you would not have needed if you had listened and obeyed.
old2soon
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Posts: 23402

Willow Springs mo


« Reply #2 on: April 22, 2015, 10:07:15 AM »

Get a butter knife you ain't real proud of. Work the butter knife in close to the screw you want to remove. As you are turning pry GENTLY with the butter knife. Once you get the 2nd one out you will KNOW how much too pry. ALL that A B S plastic in the fairing is thinner than you think it is. Take your time with this procedure. I KNOW it works cause I have an I/S and the same cursed thing happened to me. When you reinstall those brass ferrules use some liquid steel or an epoxy. Keep the mastic out of the threads. When you reinstall screws use some anti seize. If you need any new ferrules here is that part #90316-MJ1-000. Order at least one more than you THINK you need!  Roll Eyes Trust me on that!  cooldude The ferrule SHOULD remain on that screw and put a small vice rip on the ferrule with just enough pressure to back off and remove screw. RIDE SAFE.
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Today is the tommorow you worried about yesterday. If at first you don't succeed screw it-save it for nite check.  1964  1968 U S Navy. Two cruises off Nam.
VRCCDS0240  2012 GL1800 Gold Wing Motor Trike conversion
Steve K (IA)
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Posts: 1662

Cedar Rapids, Iowa


« Reply #3 on: April 22, 2015, 10:43:26 AM »

Get a butter knife you ain't real proud of. Work the butter knife in close to the screw you want to remove. As you are turning pry GENTLY with the butter knife. Once you get the 2nd one out you will KNOW how much too pry. ALL that A B S plastic in the fairing is thinner than you think it is. Take your time with this procedure. I KNOW it works cause I have an I/S and the same cursed thing happened to me. When you reinstall those brass ferrules use some liquid steel or an epoxy. Keep the mastic out of the threads. When you reinstall screws use some anti seize. If you need any new ferrules here is that part #90316-MJ1-000. Order at least one more than you THINK you need!  Roll Eyes Trust me on that!  cooldude The ferrule SHOULD remain on that screw and put a small vice rip on the ferrule with just enough pressure to back off and remove screw. RIDE SAFE.

This is all good instructions.   cooldude  Can I add a little something?  Those ferrules/nuts have slits along the sides.  The way I have done it, to prevent the JB Weld from getting into the threads is to put anti-seize on the screw, screw it into the nut and then push it (the nut with the screw) into the boss in the fairing.  After the epoxy has cured the screw will back out.
Also, when putting the speaker covers back on, do not tighten the screws very hard.  Just snug will do as the screw has a shoulder that when it contacts the top flat surface of the nut, it is tight.  If you snug it down too much, the screw is not going to want to back out of the nut very easily no matter how much anti-seize you use.  Then you will be back to doing this all over again.   Cool   
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States I Have Ridden In
old2soon
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Posts: 23402

Willow Springs mo


« Reply #4 on: April 22, 2015, 01:32:58 PM »

Thanks SteveK-makes perfect sense.  cooldude Any idea tat makes my life easier when turning wrenches is ALWAYS appreciated. These little nuggets of hard earned wisdom are WHAT makes this board rock!  coolsmiley RID SAFE.
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Today is the tommorow you worried about yesterday. If at first you don't succeed screw it-save it for nite check.  1964  1968 U S Navy. Two cruises off Nam.
VRCCDS0240  2012 GL1800 Gold Wing Motor Trike conversion
dragonslayer
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Posts: 179

palm bay fl.


« Reply #5 on: April 22, 2015, 04:46:57 PM »

Another thing I learned was to put small orings on the screws and then tighten them.The oring will keep the screw from botteming and will keep it from turning and water out of the threads
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2k IS
98 Tour
2001 Stand
Steve K (IA)
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Posts: 1662

Cedar Rapids, Iowa


« Reply #6 on: April 23, 2015, 11:40:15 AM »

Another thing I learned was to put small orings on the screws and then tighten them.The oring will keep the screw from botteming and will keep it from turning and water out of the threads

I like that idea.   cooldude  Or how about a thin fiber washer.  "Thin" being the key word.

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States I Have Ridden In
Tailgate Tommy
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Posts: 1438


2000 Interstate, 2001 Interstate and 2003 Standard

Fort Collins, Colorado


« Reply #7 on: April 23, 2015, 12:00:18 PM »

I followed these helpful hints and it worked out great. I reinstalled all the stripped brass inserts with JD Weld and coated the screws with anti seize. I also installed a Cee Bailey windshield which is a little thicker and helps eliminate some WS rattling.
In Search of a Quiet Fairing http://www.stolaf.edu/people/marshall/fairing.htm

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