5 replies to this topic

[eld101]

So I just got my 2002 Sportster LE DI. I got a great deal on it, the only thing it needs is the intake grate replaced. I have one ordered, only the bolts on the old one appear to have been stripped.

From what I can tell, the most forward bolts come down from the engine compartment just under the shaft. Looks like a large blob of silicone over them to make everything water tight. The 2 rear bolts appear to go into a plastic piece. Looks like the bolts went into plastic inserts which also must have gotten torn out.

So....my proposed solution for the front 2 bolts is to pry away all of the silicone, pull the stripped bolts out and replace them. Then recover with some type of silicone.

What I need to know is the size of the bolts so I know what size inserts I need to get ordered.

PLEASE HELP!!!

Thanks,
Eric

[Kevin Leclair]

In this case best thing to do is get the shop manual. It will give you the replacement part numbers for everything you will need.

[cwk266]

I have a 2004 sportster and the front bolt for the intake grate has broken off.I removed the nut in the engine compartment which left a piece of the broken bolt still in the hull.Does the hull have threads in it as well as having the nut on the top side?I want to be sure before taking a punch to it as it feels fairly solid

[eld101]

I have a 2004 sportster and the front bolt for the intake grate has broken off.I removed the nut in the engine compartment which left a piece of the broken bolt still in the hull.Does the hull have threads in it as well as having the nut on the top side?I want to be sure before taking a punch to it as it feels fairly solid

In doing some more investigation, I found the bolts are 6mm. The hull is threaded, which I found after trying to tap the bolts out. Getting to the nuts is a PAIN!

My hopefully last question is: Do all 4 bolts for the grate go in from below? or do the front ones come down?

Thanks!

[cwk266]

Thanks I sure am glad I did not make things worse by forcing the broken bolt through the hull.On the 2004 sportster there is one bolt in the forward position that comes up from the bottom through the hull with a nut on the top side and then there are 3 bolts at the rear position in a triangular pattern that come up from the bottom and thread into rider plate.I am not sure if yours is the same.Good luck

[eld101]

Anyone else have one in the same configuration as the 2002? I have 2 bolts up front, an 2 in the back.

Thanks!