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Reinstal windshield question
Written by skyeenter on 10/23/2010 at 05:34 pm

Any time you have a problem with reassembly of anything on the PC go to the
appropriate section at any of the online dealers onlinefiche interactive parts
and diagrams section and download and print the section for reference.

I have found the Service Manual will not get you through the reassembly. Just
not enough info about parts identification, nomenclature and reassembly detail.

Here's the section you need for windscreen reassembly. Hopefully it will go
directly to the link. Sometimes the online fiche will only take you to the
dealers site, so you may have to look it up according to the drop down boxes.

http://www.cheapcycleparts.com/model_years/541-honda-1990-pacific-coast-PC800/as\
semblies/9281

I have removed/reinstalled/changed eight windshields and only have had a couple
of problem: cross threading by PO/lost collars and short bolts.

Windscreen reassembly:

Note: There are four different collars that are critical in their placement in
windscreen assembly. Do not get these confused and in the wrong holes.
Collar(6) is oval and critical to seating the windscreen, giving flexibility for
lining up the front bolt hole.

Do not drop these parts, as you'll need a long flexible magnetic device to fish
them out of the fairings.

1. Download and print the diagrams and parts nomenclature for reference.

2. Duct(9) is in already place.

3. Tape the windscreen rubber(3) in place. Double sided tape works best after
trying other methods.

4. Rear collar/bolt assembly.
Place collar(11) on front side of windscreen plate(4), place oval collar(6) on
rear side. Note: collar(11) slides into oval collar(6).

5. Insert bolt(28) into collar/plate assembly on one side only.

6. Holding collar/plate assembly together line up on Cowl Stay and insert
bolt(28) into appropriate fixed nut on Cowl Stay. Tighten two or three turns
only. Leave enough space so the windscreen will slide easily between the plate
and the rubber.

7. Assemble and do the same for the opposite side.

8. Slide/fit/seat windscreen on collar(11) between plate and windscreen rubber.
Lift the front of plate to remove tension as the windscreen slides on the
collars.

9. Front bolt assembly.
Gently push forward/down on windscreen plate(4) and bottom of windscreen and
line up front hole. Insert collar(33)(the big round collar) in plate hole and
windscreen hole then insert bolt(28)into into collar and turn bolt two to three
turns.

10. Mid/side bolt assembly.
Insert bolt(28) into collar (1) and turn two to three turns.

11. Insert Louver, windscreen collar(10) into opening for proper alignment.
Adjust part as required. If a tight fit removal of some material by Dremel or
filing may be necessary.

12. Tighten bolts to finger tight. Using screwdriver, tighten to just past
snug, usually 1/2 to 1 full turn. Do not over tighten as these bolts place
undue pressure on the windscreen and may result in cracking of the plastic.

Stripped nut repair: solutions.

Unless the threads are completely damaged beyond use there's the possibility of
realigning them by reverse threading. This will require removal of the meter
panel for access to the cowl stay if any nuts are damaged. Just as the name
implies start the bolt from the reverse side. Make sure you lubricate the nut
and bolt as you'll be re-cutting the threads. Instead of using the OEM Phillips
head screw try a hex head bolt of the same size, as the Phillips may strip or
round off.

If the threads are beyond repair you can use Heli-Coil threaded inserts to fit
the bolts. This may require drilling out existing threads out of the nut.

Another option is to attach a same sized nut behind the stripped thread nut. It
will have to be attached (welded) because access to the nut will be limited if
the meter panel is not removed.

Lost collar replacements may be found at your local hardware store. Bolt size
is more important here than actual length. Length can be cut to size.

Good luck. skye