Rear tailight cowl

[drhach]

Hi Everyone, during the disassembly process, all three of the bolts that held my cowl, sheared off. They were all really rusty and looked like they had seen better days. Needless to say, I want to reattach the cowl, but I can't seem to get the sheared bolts out of the cowl. Has anyone ever removed these before? The back two look the were possibly inserted from the top. The front one looks like it was molded in to the piece. I wanted to ask if maybe I was missing something obvious before I attempt surgery. Thanks.

[chiphead]

I suggest you post the year make and model.

[drhach]

1978 Gs1000

I suggest you post the year make and model.

That's a great suggestion. I make that same mistake often on another forum for a different bike. I assumed this was the 1978 GS1000 forum.

[Billyboy]

We don't have a specific forum for years and models.

Sorry I can't help you.

[drhach]

We don't have a specific forum for years and models.

Sorry I can't help you.

Ok, thanks anyways. I'll unsubscribe from this forum and go home to wait until somebody starts one for my bike.

[Billyboy]

Ok, thanks anyways. I'll unsubscribe from this forum and go home to wait until somebody starts one for my bike.

Is that a joke?
This forum covers all GS's from 76 to 85. All models. Just not specificly.

[drhach]

Is that a joke?
This forum covers all GS's from 76 to 85. All models. Just not specificly.

Yes, it is a joke, in response to what I also thought was a joke on your part. I know there are no specific forums for years and types. I've been reading this forum for a few years now. Even though I don't have a lot of posts, I'm pretty familiar with "the deal" and most of what goes on here. I forgot to include that info in my initial question. When I commented about bike specific forums, I was merely referring to the fact that the bike that I own is all that I think about, and that I forget sometimes that there are other types of GS's out there besides 1978 GS1000's. As such, I usually forget to mention what type of bike I have, because for me, it is a given that it is a 1978 GS1000. I tend to forget that there are all shapes, sizes and flavors of GS out there. Please don't take offense. Sometimes my sense of humor is way too subtle for my writing abilities. This is especially true for people who don't know me.

By the way, any suggestions as to how I might get the sheared mounting bolts out the rear cowl of a 1978 Suzuki GS1000? They are still in there.

[CA180]

Could you post pics? I really have no clue in any way whatsoever as to what bolts you are refering to. But i have a 550L, so no fairing. But one thing i have learned, where there's a will, there's a way.

Post a pic, and i might be able to help you figure something out.

[Tom MLC]

Might be easier to replace the tail piece. I see 'em pop up on ebay all the time. Otherwise, you probably need to drill them out & run a bolt from the top.

[Billyboy]

Might be easier to replace the tail piece. I see 'em pop up on ebay all the time. Otherwise, you probably need to drill them out & run a bolt from the top.

That's what I was thinking.

BTW: I know what you mean. I feel the same about my 78 GS1000.

[t3rmin]

Don't you love how the lack of vocal inflection and body language complicate the written word? ;-)

[drhach]

Don't you love how the lack of vocal inflection and body language complicate the written word? ;-)

Very much so. That's why people don't line up to but my books. They wouldn't understand what I was talking about. Also, they don't line up to my books because I haven't written any. But that's not the point here. As far as the cowl goes. I am way too cheap to just go out and buy another one. My wife will vouch for my cheapness. So, unless I destroy it while trying to fix it (which is likely). I have to try to get those bolts out. Plus, I don't like thinking that the bolts may be smarter than me. I have included a picture for those of you who don't know what I am referring to. I think in the end, I'll try to drill them out and put new ones in. I think the bolts are molded in to the assembly.

[t3rmin]

Ooh. Dig that green frame!

[drhach]

I'm pretty happy with how it came out. I heard green paint makes your bike go faster. I think those caddy taillights should look good too. They fit in the housing almost like they were meant to be there. Someday the damned thing may even run.

[onchiman]

Here's a thought. First, remove what's left of the studs that are pressed into the plastic. I think a little heat might help this process. Obviously you don't want to melt the plastic but sort of "relax" it. You might even be able to cut a slot or two into the plastic to facilitate removal because it will be fixed in the next step anyway. Then get some appropriate sized bolts, place the heads in the now vacated holes in the cowl and apply a generous filling of JB Weld. This should stick the bolts in there just fine. I had originally thought drilling out the old studs and then tapping would work but this method might be easier and just as effective. Don't overtighten and use stainless steel bolts and nuts and you'll never have to worry about them rusting again.