Can't Remove Upper Fairing/Cowling, bolts just spin

[npoly]

So from everything I've read, removing the upper fairing/cowling should only take 3 minutes. I'm typing this during hour 2.

I've been able to remove the 2 bolts from the sides, but the 2 bolts next to the gauges are not coming out. I keep unscrewing them, but nothing happens.

MY guess is that there is some sort of rubber grommet on the back side that has rotted out just enough to let the bolt spin, but not be pulled out.

Any ideas?!!!! I feel like I'm taking crazy pills.

Also, this is my first Thread and Post here, so be nice.

ps I feel like I described to the best of my ability, but if photos are needed (I don't think it would help) I can upload some.

[Chuck B]

Originally Posted by npoly

So from everything I've read, removing the upper fairing/cowling should only take 3 minutes. I'm typing this during hour 2.

I've been able to remove the 2 bolts from the sides, but the 2 bolts next to the gauges are not coming out. I keep unscrewing them, but nothing happens.

MY guess is that there is some sort of rubber grommet on the back side that has rotted out just enough to let the bolt spin, but not be pulled out.

Any ideas?!!!! I feel like I'm taking crazy pills.

Also, this is my first Thread and Post here, so be nice.

ps I feel like I described to the best of my ability, but if photos are needed (I don't think it would help) I can upload some.

Sounds like you are referring to the wellnuts. They look like this...





I've learned that any bike I own that has these I immediately disassemble and apply anti-seize to the threads (doesn't take much) otherwise add a bit of moisture and the dissimilar metals of the bolt and nut (molded into the rubber wellnut) fuse together.

At this point you can try some penetrating fluid but most likely you need to get to the other side to hold it. It can be a royal pain. The other tidbit...when you go and install them do not overtighten. Heck, I barely make them snug. Also, you'll want to have a handful of extra's on hand...they don't last long. Rubber splits/cracks from UV and folks overtightening.

Welcome to the forum!

[NVGTI]

Chuck, or anyone, know what size for the front fairing? I had bought some in the past but they turned out to be the wrong length IIRC.

[Chuck B]

Originally Posted by NVGTI

Chuck, or anyone, know what size for the front fairing? I had bought some in the past but they turned out to be the wrong length IIRC.

M8 but I dont recall the length either.

[NVGTI]

Thanks Chuck - I'll have to check when I get home on what I have.

[npoly]

Thanks for the help guys. I think I have no other choice but to try and take apart the left and right side of the upper fairing in order to even reach the wellnuts (in order to grab them). I'm going to try and spray some PB Blaster in there as well.

If you have any other ideas I'm open to hearing them.

Once Again, I love owning a KLR, the bike is good, the people are great.

-nick

I'll update what I end up doing, and how it went for others to see in the future.

[wymanwinn]

Originally Posted by npoly

Thanks for the help guys. I think I have no other choice but to try and take apart the left and right side of the upper fairing in order to even reach the wellnuts (in order to grab them). I'm going to try and spray some PB Blaster in there as well.

If you have any other ideas I'm open to hearing them.

Once Again, I love owning a KLR, the bike is good, the people are great.

-nick

I'll update what I end up doing, and how it went for others to see in the future.

remove the windscreen....you can then hold the back of the well nuts...

wyman

[JYR]

I just got rid of those stupid well nuts and had to do it the way wymanwinn said

[thevanrat]

I have battled (and lost my temper) with the little buggers too. Kawi wants like 5 bucks each for em, and they are nuthin special. I know there are other sources for em, but ended up finding some at Menards for like a buck something each, but they are in USA 1/4 20 thread. Picked up some stainless Allenheads and washers, and never looked back. The one's from Menards worked fine, I will see if I have one yet in the little baggy for the part number, couple of us in a group have switched to them.

I carry one T handle allen driver that I cut down custom to fit the upper and lower allens... it's slick.

Another trick, when I had my upper/lower fairing parts all off and on a table while working on something else, I smeared a bit of Jb Weld over the area of the HOLES in the fairing plastics to make the HOLE a bit SMALLER. A day later, after it dried, I just dusted it flush with a die grinder. Now, each time I have those fairing bolts out, I routinly just replace the dang well nuts, and they fit snuggerer in the holes, and are less prone to spin it seems.

I wipe a bit of white lithium grease on the bolts to keep em happy in them things.

Just our groups experiences with three 09 KLRs.

Wyman is right, you can sort of get behind the uppers, one finger, a screwdriver tip, and some madness, but there is a path there like he said.

Careful, no swearing now!

[npoly]

Ok, so after a total of 7 hours (over 2 days) I finally got the cowling off of the bike. ugh. I was exhausted. So here's the recap.

I took the windshield off and tried taking out the bolts normally, just spun. I attempted to grab the wellnut with some pliers, they just spun. Tried giving the bolt an couple of love taps with a hammer to try and break any rust bonds that had occurred within the bolt and nut and still nothing. I even brought the Dremel out, but couldn't get a good angle.

Finally I was able to barely squeeze in a mini vice grip to grab the wellnut and i twisted the bolt. In doing so I destroyed/ripped apart the wellnut. It was a bitch until the very end. The bolts and nuts had seized.

All in all. I got new hardware for the wind shield and I ordered new wellnuts for the cowling (should get them in a couple days). You can make damn sure that the new hardware with have anti-seize on them.

Time to relax.

[WiRider]

Gen1, Gen2, both? Which years have these ... things!?

[npoly]

Mine is a Gen2