Ok,

After procrastinating for years, I finally bought my first motorcycle, a 2005 XL883. It's a sweet little ride, and I'm really liking it.

I go to take the derby/clutch cover off, and the screws are frozen. They're T27 torx, and the driver is twisting/breaking before they turn. So far I've got 1 of the 6 to loosen up.

Any secrets to getting these out? A little heat maybe? Am I missing something here?

Cheers,
John

Those screws are a pain in the a**. I would suggest getting some replacements before you continue, I stripped out two taking my cover off.

What I had to do was slightly tap on the end of the driver ( screwdriver, ratchet, ect..) with a hammer as I turned it. Turned out to be loctite on the threads, the tapping helped to break up the loctite while I turned them.

Good Luck

Had to use an impact on mine, and one stripped so I grinded a slot in it then replaced it. I think replacing the stock ones for a better grade steel is a good idea. Most of the ones I have taken off ( cam, primary, fender, shock mount, all I've messed with) are a bit chewed and seem like a super cheap grade metal.

Impact driver with a T27 bit. Failing that, drill the heads off leaving a stud behind when the cover is removed that can be removed with vice grips.

Fox

Yup, same thing happened to me. I F'd with it till I got all out but one, and had to cut it out.
I carried one of the damaged ones up to Ace hardware and got chrome allens to replace them.
(I was gonna do that anyway...I HATE torx!!!)
Everytime I work on by bike, I throw away the Torx and replace them with allens...torx are as useless as wasps...

Yup, same thing happened to me. I F'd with it till I got all out but one, and had to cut it out.
I carried one of the damaged ones up to Ace hardware and got chrome allens to replace them.
(I was gonna do that anyway...I HATE torx!!!)
Everytime I work on by bike, I throw away the Torx and replace them with allens...torx are as useless as wasps...

Torx work when properly used. They allow for better engagement of the tool. Just have to use them properly. I've never had a torx bit strip when used properly.

The previous owner of my bike used red loctite on my derby cover. I was finally able to get them out using some heat and some banging. I bought a box of t27 bits from home depot (screwdriver style) and banged them into the bolt. Then heated the bolt with a torch. Then quickly pulled out the hot bit and inserted a fresh one on a socket wrench and they came out no problems.

Yup, same thing happened to me. I F'd with it till I got all out but one, and had to cut it out.
I carried one of the damaged ones up to Ace hardware and got chrome allens to replace them.
(I was gonna do that anyway...I HATE torx!!!)
Everytime I work on by bike, I throw away the Torx and replace them with allens...torx are as useless as wasps...

I am with you Blaze, Torx suck, and worst yet if they are in something Chrome.

I know they work, but I just think they are in the wrong application.

Wow - you guys are awesome! Much thanks! I guess I'm not the first to struggle with derby cover screws.

Here's my plan; I'll put a bit of PB Blaster on each screw and let it soak. I'll take the bike for a ride to warm things up. Then, I'll go at them with the T27 while tapping the driver with a hammer, applying heat if needed.

If all goes well, I'll be able to get a look inside, see that I put the right amount of tranny fluid in, and put my nice new HD derby cover on.

Thanks All!

JR

Here's my plan; I'll put a bit of PB Blaster on each screw and let it soak. I'll take the bike for a ride to warm things up.


That should work. Be careful, they'll probably vibrate right out while your riding. :tour

Seriously, this seems to be one of those common issues with these bikes. Mind boggling that those little bolts have caused so many (myself included), so much anguish.

Next up, you get to do battle with the rubber gasket on the inside of the cover. There is a whole bunch of posts on dealing with this. Some suggest a dab of grease to hold it in place.

It worked! I dripped a bit of PB Blaster on each screw, then let it sit a few days (and rode the bike now & then). This weekend I dripped a bit more PB Blaster on each screw, and rode the bike for an hour to warm up the tranny. With a good quality T27 socket, and the tranny nice and warm, each screw popped and let go! None stripped or broken!

A word of caution on PB Blaster - it melts gaskets. It's much better at loosening frozen parts than WD-40, but don't spray it everywhere. It will melt every bit of plastic, rubber, and gasket material it finds. That's why I apply it in drops off a popsicle stick. I think the warm tranny helped loosen things up too. I didn't have to use a heat gun.

I also learned that if the bike is on the kick stand when you pull the derby cover off some tranny fluid will spill out onto the ground. But, if you have somebody hold the bike up straight, or leaning a bit to the other side, you don't lose any.

Lessons learned!
JR

go to home depot and get a screw stripped remover (or some such shit) drill bit they remove all problem torx

Just went through this myself. Timing chain inspection cover was leaking. A wise forumite suggested replacing the cheesy rubber gasket with the paper/metal sandwich one. Part # 34761-04A. The $2 gasket came in a kit with the gasket and slightly redesigned inspection cover. $23 - ouch. While I was at it I decided to change the tranny/primary fluid to Red Line 75/90. The derby cover gasket had me stressed out until I put a little permatex on the back of it to hold it in place. I then tried torqueing the torx 27s in accordance with the manual. Two of them stripped (the torx heads, not the threads) before I reached the torque. Grrrrrrrrrr. I went and bought some 1/4 -20 allen head machine screws and replaced all six cause I was worried about uneven torque on the derby cover. This time I let the torque wrench sit and torqued them all by feel with the allen wrench. Now I'm happy. My sporty's got new oil, the oil is staying inside the case, and I'm satisfied My primary/tranny will be good for another 4000 miles or so. :tour