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1st November 2009
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Know It All
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Join Date: Oct 2009
Posts: 151 Sportster/Buell Model: 2006 xl1200r
Reputation: 182
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Allen Heads on Primary Chain Inspection Cover
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?
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1st November 2009
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Senior Master Custom Bike Builder
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Join Date: Sep 2005
Posts: 4,632 Sportster/Buell Model: 1250R Hammer Performance Sportster/Buell Year: 05
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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.
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Leo 05 Hammer 1250R San Jose, CA
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1st November 2009
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Senior Chief Harley Engineer
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Join Date: Apr 2008
Location: Buffalo, NY
Posts: 1,021 Sportster/Buell Model: XL883L Sportster/Buell Year: 2007
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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.
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--Trevor
2007 XL883L- Pearl black or nighty tins, V&H short or side shots depends on my mood lol, Drag bars, fwd. controls, mini speedo, wire tuck, coil and ignition moved, solo saddle, other stuff moved/removed.
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1st November 2009
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Banned
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Join Date: Jul 2009
Location: a liddo northwest of you
Posts: 6,363 Sportster/Buell Model: Sportster Sportster/Buell Year: 2008
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They are number 27 torx heads if your back is new and hasnt been changed, so they could be allen heads
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1st November 2009
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Brass Nut
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Join Date: Feb 2005
Location: Western Weald
Posts: 30,744 Sportster/Buell Model: XL1200V Sportster/Buell Year: 2013 Sportster/Buell Model #2: XL883C … long gone Sportster/Buell Year #2: 2005 Other Motorcycle Model: FXDB … gone! Other Motorcycle Year: 2012
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Quote:
Originally Posted by MonkeyMouse
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.
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Quote:
Originally Posted by AsSeenOnTV
They are number 27 torx heads if your back is new and hasnt been changed
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Quote:
Originally Posted by Peg Scraper
They should be torx head bolts unless someone changed them to allen head bolts.
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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?
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Folkie
Super Moderator
'The green machine'
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2nd November 2009
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Chief Master Mechanic
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Join Date: May 2007
Location: Eagle Point, Oregon
Posts: 478 Sportster/Buell Model: 883 Custom Sportster/Buell Year: 2005
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Quote:
Originally Posted by Folkie
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?
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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... 
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2005 883 Custom, 16" apes, Arlen Ness Big Sucker, w/EVO 8" round cover, National Cycle light bar, Mustang Wide Studded Solo Seat and Pillion, Khromewerks 2" drag pipe slip-ons, Cycle Visions 30" sissy bar, 3" tank lift, HB125XL Hydraulic Primary Chain Tensioner. Riding is my life. Blinging is just a hobby.
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2nd November 2009
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Senior Chief Harley Engineer
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Join Date: Apr 2008
Location: Buffalo, NY
Posts: 1,021 Sportster/Buell Model: XL883L Sportster/Buell Year: 2007
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Quote:
Originally Posted by Folkie
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?
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Ya know what, I believe your correct.  |
2nd November 2009
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Banned
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Join Date: Jul 2009
Location: a liddo northwest of you
Posts: 6,363 Sportster/Buell Model: Sportster Sportster/Buell Year: 2008
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yup! Folkie is correct again.
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1st November 2009
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Land Speed Record
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Join Date: May 2009
Location: MoCo Co., Wisconsin
Posts: 756 Sportster/Buell Model: XLH1200 Sportster/Buell Year: 1994
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They should be torx head bolts unless someone changed them to allen head bolts.
Get yourself a hand impact driver.
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1st November 2009
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Senior Master Custom Bike Builder
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Join Date: Mar 2007
Location: Calgary, AB, Canada
Posts: 4,303 Sportster/Buell Model: XL1200C Sportster/Buell Year: 2006
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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.
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Getting through the Break-In Miles Sucks!
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