Buy an impact gun . Quarter inch drive w t27 bit. These can suck to get off.
Sears battery operated impact gun for future removals.

 

This is the best way.........

 

Drill it!

 

this seems to be common problem on all harley models i've seen this many times the bolts just too tight to be removed without stripping torx head replace with allen heads for sure, usually the problem is amount of torque on bolt, cutting slot with is great idea but i've found it still very hard to remove because of torque on bolt, also using dremmell tool in such tight work space without scratching cover can be tough, same with trying to tap out with chisel, two methods i use, first at point you know the torx head is going to strip try a hammeer style impact wrench gently usually not working but nothing to lose after this the torx head is done, paln b, use left hand drill bit just larger than bolt threads, got 10 piece set for 10 bucks, once bolt head gets thin torque pressure relieved bolt spins out with drill bit, never going all the way through to cover, using standard drill bits you have to be carefull to not drill into cover, left handers have worked everytime for me never a scratch, no dissrespect for anyones ideas hope this helps someone

 

allen vs torx is an age old argument. theoretically, the torx can handle higher torque loads than the allen. in reality, people strip them out using the wrong size bit, or cheap bits that aren't exactly the right size (a harbor freight t27 may not be equal to a snap on t27)

however you get it off, (drilling the head off and then removing the shaft by hand worked for me), when you go to reinstall, do 2 things: first, use a dab of anti-seize on the new bolts, and secondly, do not torque these down super tight. it is not high pressure oil behind it, so snug is perfectly fine. torque spec is 84-100 inch lbs (NOT FT/LBS). and tighten them in a star pattern, snug first, then final torque the second time.

after the first one that i had strip, i've been doing it this way for over 10 years and haven't had a second one strip yet. and yes, i'm still using the hd torx screws.

 

99 % of the time you can use an allen wrench to remove stripped out torx head bolts.

 

This.

Torx screws are fine as long as you use the proper size quality bit and good technique. The problem is the nut behind the wrench.

 

I had the same trouble you had on the first service. The next time I removed it with this and had no problems

http://www.sears.com/shc/s/p_10153_12605_SPM217385939

You hit this ratchet with a hammer which simultaneously turns the torx. The hammer drives it into the head so it won't strip. Worked great on the 10,000 miles service.

 

I've seen enough stripped out allen & Torx head bolts I picked up a remover set , Cool little gadgets look like an allen but the working is tapered so you tap it into the head till it bites and out they come . Saved I don't how much time dealing with monkeyed up bolt heads .

 

Explicitly picked up this (Craftsman) yesterday, which was missing in my new tool set:



Yes, T25 might trick you into proper fitting, but it is way too lose.