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  1. #1

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    Angry Help - Bolt in fuel rail not coming out due to bad threading

    Hi Guys,

    Just finished installing a new X Charger in my 2007 RXT, everything went smooth and all I was missing was to put the injectors. I removed bolt in the back but when I tried to remove the one in the front I found out that the thread is messed up (someone over tighten the bolt and messed up the threading). What can I do at this point? The ski has warranty but don't know if it will cover this issue.

    Thanks


  2. #2
    MILF -Most Interesting Little Female Rxpx-Milf's Avatar
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    Here are a few suggestions you can try...
    drill the head off. then remove the stator
    Or cut a small slot into it with a dremel, then use an impact driver tool to get it out (not an impact gun, the kind you hit with a hammer)

  3. #3
    Nothin' better than Doo'in it! BigDaddyRXP's Avatar
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    Take it into the dealer and act stupid to see if they will replace your intake manifold... that baby is like $500 retail

  4. #4

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    Thanks guys, 4 weekends without riding and now this stupid fuel rail bolt issue.

  5. #5
    Nothin' better than Doo'in it! BigDaddyRXP's Avatar
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    Quote Originally Posted by 556SBR View Post
    Thanks guys, 4 weekends without riding and now this stupid fuel rail bolt issue.
    You could possibly drill & tap the threaded insert out to accept a larger bolt size... but I would act dumb and take it to the dealer for a manifold replacement!

  6. #6
    Gotta love this sport! 05Limited's Avatar
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    Quote Originally Posted by 556SBR View Post
    ... I removed bolt in the back but when I tried to remove the one in the front I found out that the thread is messed up...
    You might try taking a screwdriver and prying upward slightly as you turn the torx bolt. Using a moderate amount of upward pressure as you turn the bolt may allow you to remove it. If you get the bolt out you'll find that the brass insert is not very deep, but the plastic boss that it is pressed into is. Using the proper metric tap may allow you to clean up the threads enough to make it usable.

    If this fails, then follow bigdaddy's suggestion and play dumb. It's worked for me before... but then again... playing dumb comes rather easy for me.

  7. #7
    Gotta love this sport! 05Limited's Avatar
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    Oops!... here are a couple of pics:
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  8. #8
    Fast & Loud meeper's Avatar
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    on my buddies PX the brass boss came messed up from factory it just spins in the plastic, all i do is put a pair of vice grips on the plastic and it squeezes the insert enough so the bolt comes right out, just dont kill it when putting back together thers is no need to hammer down on those bolts

  9. #9
    Dave Sharp dav_dman's Avatar
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    looks like you could pull the insert, tap it and epoxy it back in. I dont trust dealers.

  10. #10

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    Quote Originally Posted by 05Limited View Post
    You might try taking a screwdriver and prying upward slightly as you turn the torx bolt. Using a moderate amount of upward pressure as you turn the bolt may allow you to remove it. If you get the bolt out you'll find that the brass insert is not very deep, but the plastic boss that it is pressed into is. Using the proper metric tap may allow you to clean up the threads enough to make it usable.

    If this fails, then follow bigdaddy's suggestion and play dumb. It's worked for me before... but then again... playing dumb comes rather easy for me.
    I was able to remove it using your technique, but even after it was out the plyers could not hold the insert to remove the bolt. Finally I was able to do it with bigger plyers and applying a lot of force. I am going to get some JB Weld and put the insert back in so that I can ride tomorrow, will focus on getting a new intake manifold during the week.

    Thanks again.

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