I bought a few items for my new 07 street bob last week, I installed the exhaust, screamin eagle air cleaner and V&H fuel pack, I also bought a black finned derby cover, since you remove the derby cover to add oil I figured I would change the oil while im at it. I drained the oil, then went to remove the stock derby cover and I cant get the torx bolts to budge. I have broke 5 T27 torx bits so far, 1 craftsman 1 snap on and 3 husky and not one bolt will budge. I called the Harley dealer and they told me to drill them and use a easy out.
I cant believe they told me to do that, I cant move the bike because I already drained the oil.
Is there a trick to getting these bolts out, (yes I am loosening them, turning to the left).
Is this something that warranty will cover, I bought the bike new 3 weeks ago.

 

Something doesn't sound right. I replaced my derby cover in about 5 minutes, like you I used a T27 and had no problem. Sounds like maybe they are over torqued, or lock-tited down. I don't think drilling them would be a good answer, you may have to fill it up with oil and take it to the dealer. You should not loose any oil when you change the derby cover, if you do you've got to much oil. Make sure you buy the flat gasket, the o-ring type will not work with the replacement covers.

 

maybe a torx tip anda pnuematic motor ? Keep pressure in while turning or also try a impact wrench and a torx tip.

 

you may want to carefully tap on the the rachet with a hammer while you try to turn it.. May require another set of hands. Another option is to try to tighten it slightly just to break it loose and then try to loosen it, sounds strange, I know, but some times this works. An impact driver may also work if you can find the right size torx bit for it. Good luck!

 

I wish I could get oil back in, but you add the oil through the derby cover, I do have the new gasket for the cover. Im going to call my dealer again and talk to a manager because somethings not right, the cover on my sportster came right off. I believe they supposed to be tightned to 30 inch pounds.
I just dont have any way of moving the bike now. I did try a impact, The one you hit with a hammer but the bit broke.

 

I also had the same problem with only one bolt. I used a dremel tool and slotted it then removed it with an impact driver. The rest came out fine. By your posting you did use a quality (non-worn) T-27.
that is imperative.
Good Luck!

 

Sounds like they were overtorqued at the factory. I was kinda forced to replace my derby cover after a droppage incident, and mine came right off.
If I understand correctly, the bits are breaking but the heads of the screws are not messed up? If that's the case, I'd not go the easyout route if it were me. Maybe try a better quality torx. Chase down a snapon truck =P

Or heat 'em up somehow (not sure how a torch would to with the chrome?)

wt.

 

I used a snap on and craftsman, the heads are fine on the bolts so far, thats what im worried about, I dont want to damage them. Then I would really be screwed.

 

Seems to be common problem from the factory. I had to drill one out on a friends Sportster and two on my Dyna when it was new. When you finally do get them out, I recommend replacing with Allen head bolts and I use a little anti-sieze on the threads.

 

try torquing the rest of the bolts to 108 inch pounds and then try loosening the bolt.