Nightmare with plastics and seat

[outlander]

I have a 2015 pcx. The original owner dropped it and scuffed the plastics. I have ordered and received all the plastics. The rh lower fairing, rh black plastic and rh upper fairing around light. I also got the pcx service manual today. The plastics are terribly engineered to fit. Its like I have to removed the plastics at the back of the scooter to get to the front. The only piece left to remove is the upper fairing.

According to the service manual my next step is to remove the seat via 4 nuts. I removed the 2 right nuts that attach to the seat, while the 2 left nut were very stiff and ended up breaking their connection with the seat on the other side of the seat plastic. So on the foam side the bolt is attached someone, now the bolt has come off and all that happens when I try to remove the nuts is that it freely spins. How can I remove the 2 nuts without cutting up the seat?

[scudder]

I presume the bolt has become loose under the foam and cover. Just undo some of the staples with a flat head screwdriver and locate the nut. Staple it back down after :-)

[outlander]

What would you staple it back down with? A normal stapler or a staple.gun?

[Mel46]

Staple gun. I don't have a 2015 version but on the 2013 version the seat comes off easily by way of 2 bolts on the front connect ted to the hinge. I can't believe that you would have to do anything extra. That would be nuts!

[WhiteNoise]

a little "play on words" hey there Mel?
Sorry, outlander. I know you're concerned, I would be too. You'll get it all sorted out, I have faith. Pull the staples around the area and grab those pieces out. I wish I could fix open clothing seams with staples, but nooo....must sew. Not fun.
Good Luck with yer plastic replacements and share a "proud pic" when yer done!

[outlander]

It is really tearing me up dismantling the pcx.

I removed enough staples to slide my fingers in and touch the other side of the bolts. They are headless. So the bolt thread us just spinning.

[Mel46]

Vise grips.

[outlander]

Vice grips wont work becausr the plastic from the hinge and seat comes out too far, i cannot get the vice grips past the plastic. I cannot remove the seat staples at the front as that is where the hinge is.

I am currently removing all the staples I can get to so I can fold the seat foam forward so i can access the top of the headless bolts, maybe i can stop them spinning some how.

[WhiteNoise]

Take advantage of that! "If" your seat is uncomfortable, and yer stripping off the vinyl, maybe just maybe? You want to "Make That Change?" And add foam or...whatever? Just sayin'

I can tell you're getting frustrated. Understandable. Try to enjoy the tear down. Take your time, have a beer. Then Go back to it. Easy for me to say. But I've been there too.
Go ahead! Let it out/Shout it Out! Happy Thanksgiving! (Whilst Whispering..You SOB!!)

Today...You'll get away with that, No problemo

[Mel46]

All i can say is Good Luck with it. I never thought i would be happy that i didn't purchase the most recent model. My 2013 sounds like a piece of cake in comparison to the 2015 version. My seat comes off with two nuts, or i can remove it with the hinge still on by removing two bolts.

[outlander]

Ok, well the good news is that it is all bad together minus the seat.

The bad news, I have 2 silver screws left over....


I have found that the honda service manual was useless. It told me I had to remove the seat, once removed I found out it never had to come off at all.

The plastics I replaced were rh lower fairing, rh black plastic, exhaust cover, rh front fairing.

I'm pretty sure the spare screws were from the front fairings, I am not too sure and I am not removing the plastics anytime soon.

I'm going to get staples for my staple gun tomorrow and I will try and refit the seat material and foam.

The top of the 4 seat bolts have a square flat head, which is inside the plastic seat pan. When I used the ratchet to loosen the nut, the square flat head stripped the plastic and was just rotating inside the seat pan. So I had to remove the seat foam and use a soldering iron to melt the plastic around the seat bolt. Only then did the seat lift off the hinge.

If the seat material goes back on successfully, the seat will only be held on with the 2 right bolts. If its not secure I will have to order a new seat and hinge.

I broke a fair few clips, I followed the service manual to the word and it was impossible to pull out the plastics without breaking tabs. My fingers and thumbs hurt.

[Mel46]

The screws could also have come from the foot rest area, under the rubber. But if you can't figure out where they belong, just say "Screw it", and go riding. Don't just bolt out of there though. (Ok, I just had to throw those in there. A little humor is good for the soul).

[outlander]

Screw it lol, I'm done with screws for now.

All of the screws under the rubber mat are present, i'm pretty sure its up front somewhere.

I put the seat back together with a staple gun and it looks like new apart from that only 2 of the 4 bolts are present on the seat. The seat seems ok. I will wait till a used cheap 2015 seat pops up on ebay and replace it.

[chainsaw]

i bet the screws are from the front edge of the side panels, in near the fuel tank. i've forgotten those ones a couple of times now.

[JohnL]

Exactly the same two screws my son and I missed when we put new shockies on the PCX.