Had this happen myself -- all the bolts came out but one. I was able to drill the head off, take off the derby cover, and then it was easy to remove the problem bolt.

Best long-term solution is to replace with allen-head bolts. Don't get them too long - measure against the removed torx to be correct.

Also, never put locktite on these. The problem isn't having them fall out, it's breaking them loose when time to take the derby cover off.

I use Permatex anti-seize each time I put the allen-heads back in. Never had one fall out yet.

Also, don't use a ratchet wrench to torque them, they don't need to be overly tight. Use an ordinary L-shaped allen wrench -- lets you get them "tight enough" without over-torquing.

 

I had problems with 2 right before an overnight ride. Had to drill out 1 and the other my Grab-It set worked. I agree, they seem awfully soft.

My problem was probably compounded by using loctite (per habit of everything on an HD) vs. anti-seize. I didn't torque them very much, and used harder chrome ones from HD so it should be interesting next time.

Oh and the other laughable part: I did it at the 5k service when I could have waited until the 10k. Just my luck...

 

Garbage chinese chewing gum screws and bolts- Thanks for s... HD.
I had 2 stuck -cut a slot w/dremel then heat then impact driver. LOTS of M/F'ing HD
Now spare GOOD allen bolts in stock to replace every HD s..t screw as it comes out.