I need to remove my intake manifold
on a 1998 Buell Cyclone M2.
Fasteners are super tight! Can’t tell if they are Torx or Allen. Seems like I also need a special tool given how tight they are arranged. Ugh!

Buell intake

 

90% sure those are gonna be 3/16" Allen. Take a single "L" shaped Allen key and cut off some of the short end.

 

3/16 allen wrench and trim the short end down to get in there.

Dang might be a 1/4 but thinking 3/16.

Just an example
WP

 

Thanks great idea!

 

You can also cut a short piece off the and insert it in the fastener then use a small open end wrench to turn it.

 

The 3/16 allen swims inside the head of these
fasteners. Upon closer inspection I think
someone replaced these with Torx heads either
T40 or T45’s.

 

That does look like it may be a Torx. Same tactics for removal.

 

Sadly it looks like the stock hex bolt that someone stripped the hell out of. Try some liquid wrench or other type of nut buster and let it sit awhile. A little pen torch to get a little heat on them will help too. Just removed mine a few hours ago and I'm pretty its a 1/4" hex...but I just know which one of mine to use and didn't actually look at the size

 

So correct. The 1/4 allen heads have been badly damaged. I used a shortened allen to gain access after solvent and pen torch to no avail. Unable to gain a respectable purchase on these burgered fasteners

My next bright idea is to cut the manifold off
to better tackle to issue since the manifold is for an S&S carb and I’m using a stock CV 40 mm so I can waste it ☹️

 

1st thing I'd try is a long ball end allen from the other side, up and across. If that fails then a small pair of quality vice grips should be able to get them.