Pan America top box mounting issues

[The Prof]

I have an issue mounting the Harley aluminum top box on my 2024 Pan America Special, the rear mounting holes lack threads, anyway the dealer ordered a new tail section, but it's the same and Harley isn't responding, any help?

 

[CruisinOnPan]

Looks like Harley switched to smooth cylinders for the rear mounting points mid-2024, which is why the holes are unthreaded. Some riders have tapped the holes or used thread inserts, but it's a bit of a DIY fix. If you're up for it, you can try that, but I'd double-check with your dealer to avoid any warranty issues.

For a visual guide on top rack installation, you might find this video helpful:

 

[agentgreen75]

Known issue on some 2024 Pan Americas, the rear mounting holes come unthreaded. Since the replacement tail section's the same, a lot of owners just tap threads themselves or use rivnuts to get the top box mounted. Not ideal, but it works, and Harley's been slow to address it. Hope this one helps

 

[DualSportPan]

It's a common problem where threads can occasionally be machined incorrectly at the factory. You might want to try installing helicoils or, as a temporary solution, use self-tapping bolts. The factory should cover this under warranty, as it's definitely a manufacturing defect.