Can't Remove Windshield

[billyboy]

2008 Nomad.

I was getting the Nomad ready for the winter this past weekend and could not get the windshield off. I wanted to remove it to clean behind it and possibly remove the sub shield.

I was able to remove all but the 2 upper adjustment bolts. All the bolts came loose easily except for the left and right upper adjustment bolts. Without being able to remove those I can't get to the upper bolts that attach to the triple tree.

The 2 bolts turned slightly and then would not budge. Are these fixed bolts or is it just a coincidence that the dealer cross-threaded both upper bolts?

[Yellow Jacket]

I would get some thread penetrating oil and apply it to the two bolts. Let it soak, maybe even overnight. Apply some more and gently turn the bolts back and forth. Don't force them. Hopefully, the dealer didn't tighten them down so much that they galled the threads.

Good luck.

[bobhamlin]

I have a '06, so just a caution if the '08 is different.

Soak the bolts with penetrating oil and tap them to help the oil infiltrate.

Make sure the allen wrench fits and is well-inserted-- then lefty-loosey.

Even if cross-threaded, they should work themselves out on the path they went in on.

Perhaps using a cheater on the allen wrench for more torque might help. I can't believe that you'd be able to break those bolts before the wrench snaps.

Good luck.

[billyboy]

Originally Posted by Yellow Jacket

I would get some thread penetrating oil and apply it to the two bolts. Let it soak, maybe even overnight. Apply some more and gently turn the bolts back and forth. Don't force them. Hopefully, the dealer didn't tighten them down so much that they galled the threads.

Good luck.

I was able to move them slightly, then they just refused to budge. All other bolts came right off. I'll put some penetrating oil on tonight and try again tomorrow.

[cactusjack]

Originally Posted by billyboy

I was able to move them slightly, then they just refused to budge. All other bolts came right off. I'll put some penetrating oil on tonight and try again tomorrow.

Make sure you have a good allen wrench and get a good bite on the head, or your troubles are just beginning...

Let some penetrating oil soak overnight and give it another go. Once you get the bolts out, you might want to chase the threads with a tap to make sure they are clean.

[billyboy]

I think you're right about the troubles. I do have a good set of Allens. I was able to get the top left bolt out tonight - cross-threaded at the dealer.

The other moves a quarter turn and stops dead. That's how I started stripping the head. It broke loose on the initial turn, then seized and the key slipped.

I'll try to remove the windshield from the brackets and work on getting the bolt out.

Will try to call the dealer and see what they'd be willing to do, but I already have it winterized. Of course, they're the ones who cross-threaded these!

[macmac]

PDI techs crossed them or galled them. Work easy and you will get it out.

If not tape over the area and cut the bloomin head off, remove the screen and cut a slot towind the rest thru. You might need to run it in so far and cut it again, but one way or the other you will get it out.

Definately chase these threads, and use antiseize on the install on every last one of these ss bolts.

[AlabamaNomadRider]

I recently removed my windshield so I could take it apart and clean it. There were only four bolts to remove the windshield. Two on each side. I didn't mess with any other bolts. Mine came out like a breeze.

[Cajunrider]

I was fortunate with mine also. I removed the screen last week and took it apart to clean between the upper and sub screens. I then lowered it to the lowest setting. I had it all the way up but that doesn't work very well when it gets covered with bugs and you are traveling with bright sun in your face or at night facing approaching headlights. Much better to be able to look over the top of the screen IMO.

[dogdoc]

Get you a 3/8 drive allen tip bit at wally world and you can put more torque than an allen wrench plain. Seat it as deep in the allen socket as possible.

[cactusjack]

Originally Posted by Doc (Lonewolf)

Get you a 3/8 drive allen tip bit at wally world and you can put more torque than an allen wrench plain. Seat it as deep in the allen socket as possible.

I'd go one step further and suggest you buy a quality set of 3/8" allen bits. Craftsman, Snap-on, MAC, etc. I've rounded off cheap ones before.

There are a number of metric hex socket bolts on these bikes that can be a bugger to break loose.

[billyboy]

Originally Posted by macmac

PDI techs crossed them or galled them. Work easy and you will get it out.

If not tape over the area and cut the bloomin head off, remove the screen and cut a slot towind the rest thru. You might need to run it in so far and cut it again, but one way or the other you will get it out.

Definately chase these threads, and use antiseize on the install on every last one of these ss bolts.

I have a screw extractor set. Would it be better to try that? Perhaps drill the hex out and use the extractor bit in that hole?

I also thought I might try to cut a slot in the buttonhead and use a big flat blade screwdriver with a wrench on it.

It only turns maybe a quarter turn. It is too close to the bracket to cut the head off.

[billyboy]

Originally Posted by cactusjack

I'd go one step further and suggest you buy a quality set of 3/8" allen bits. Craftsman, Snap-on, MAC, etc. I've rounded off cheap ones before.

There are a number of metric hex socket bolts on these bikes that can be a bugger to break loose.

I have a set of Craftsman metric Allen key wrenches and 3/8" drive Allen sockets. I prefer to use the keys first because it's too easy to use too much torque with the sockets. Tried both. The hex head is stripped.

[cactusjack]

Originally Posted by billyboy

I have a set of Craftsman metric Allen key wrenches and 3/8" drive Allen sockets. I prefer to use the keys first because it's too easy to use too much torque with the sockets. Tried both. The hex head is stripped.

I have, on occasion, driven a Torx bit into a stripped hex socket head bolt. Something else that is useful is an impact driver. Not an air impact wrench, but an impact driver that you strike with a hammer. You can generate a decent amount of torque with one of those.

Stripped the bolt head? Oh, that's not good. With all that expensive chrome, you really have to be careful what you do. You could use a drill bit roughly the same size as the threaded diameter of the bolt, and drill the head off. Then you could separate the windshield from the mounting bracket and work on the bolt.

[billyboy]

Glad you mentioned the impact driver - I do have one. And the torx idea might work too. There's enough hex shape left to grab.