Trying to change my transmission oil via Primary Chain Inspection Cover. Can't budge the allen head screws that hold it on. Tried electric drill with #3 allen head but it won't budge. Does anybody have any advice on how I can loosen theses screws?

i had the same issue on mine when i tried to remove the cover after a ride. i let it cool down for a while and came off with no problems.

They are NOT allen heads, you will strip them in a heart beat. They are either, #25 or #27 I forget which, Torx bit head. Do it cold and use a good firm pressure inwards as you slowly but firmly turn them out.

They are number 27 torx heads if your back is new and hasnt been changed, so they could be allen heads

They should be torx head bolts unless someone changed them to allen head bolts.

Get yourself a hand impact driver.

http://upload.wikimedia.org/wikipedia/en/thumb/4/40/ImpactDriverWithBits.png/250px-ImpactDriverWithBits.png

Whatever style they are, If you didn't put 'em in, they may have locktite on them.

What I would do is hold a soldering iron on the head of the bolt for a few minutes and they try and remove.

Do NOT put locktite back on them when you get them out.

Do you have the Factory Service Manual (FSM)? If not, get one and make sure to follow the torque values and sequences.

They are NOT allen heads, you will strip them in a heart beat. They are either, #25 or #27 I forget which, Torx bit head.

They are number 27 torx heads if your back is new and hasnt been changed

They should be torx head bolts unless someone changed them to allen head bolts.

Are you all sure about this? Mine are 5/32" allen heads.

The screws on the the clutch inspection cover are T27 Torx, but the chain inspection cover has allen heads.

Mike, what year bike have you got?

Are you all sure about this? Mine are 5/32" allen heads.

The screws on the the clutch inspection cover are T27 Torx, but the chain inspection cover has allen heads.

Mike, what year bike have you got?

Folkie is absolutely correct. Hey Folkie, if I remember right from another thread, Mike has an 06 xl1200r, which means your answer should still apply to his scoot as well. But, I don't know what he means by a "#3 allen head." Is that metric? Anyway, if those bolts are really stuck in there, a 5/32" allen socket on a breaker bar will work. Been there and done that on a friend's scoot... :wonderlan

Be careful.you dont want to strip them OR break one off,Loctite on them probably.IF its red loctite you will have a job.I personally had to strike a arc on the bolt with my tig torch to get enough heat to loosen the red before.TRY HEAT.

I think they are hex head bolts like Folkie said.

The soldering iron trick will help get em out, sometimes for really stuck bolts you can heat it and then hold a bit of wax (real wax) on the bolt head, as the bolt cools it draws the wax in around the threads helping to loosen the bolt.

H1

Are you all sure about this? Mine are 5/32" allen heads.

The screws on the the clutch inspection cover are T27 Torx, but the chain inspection cover has allen heads.

Mike, what year bike have you got?

Ya know what, I believe your correct. :doh

yup! Folkie is correct again.

if you need heat but don't want to do damage to, the primary case put a allen wrench on it heat the wrench and the heat will transfer to the fastner it does work I've use it myself on a firends sporty never had a problem getting mine off on any of my three sportsters I've had over the years.

The were allen heads. I used an allen head attachment that fits into a screwdriver and put a vice grip on the screwdriver after spraying some liquid wrench on them. I tried a couple of times (very carefully) with an electric drill with an impact setting at first and they wouldn't budge. Came back an hour later tried the screwdriver and vice grips and they finally came out and then after the oil change they went back in with no problem. There was no lock tite on them.

So, if I understand you right, you have a set of screwdriver bits, including 'allen' bits numbered #1, #2, and #3, and #3 was the closest to fitting?

A proper set of allen keys would be better. :geek

Yes that's about the size of it. The holder that it fits in says #3. I have regular allen keys but when I tried to use one (with a vice grips attached) it started to bend and I wouldn't have been suprised if it snapped in half if I had kept forcing it.

MonkeyMouse: 2006 xl1200r