i have a 2005 heritage and i have to replace the rear disc, i've got the rear wheel off and i've got the new disc and new torx screws/bolts, but i can't remove the old torx bolts i have soaked them in penitrating oil but have still managed to shear off 4 torx sockets, the bolts just ain't budging anyone got any ideas.

 

Try heating the bolts with a heat gun.

 

Pipe wrench... once you get them broken loose, use the torx

 

1) Impact wrench with a higher quality torx bit (and a spare or two)
2) Torch to heat the bolt and release the thread locker

I've never had to resort to the torch method but I've been close.

And when you reinstall, clean that factory threadlocker off the bolts (if any) and use blue (242) loctite, not red, or you'll be going through this all over again the next time.

Some guys may argue with my loctite recommendation and I'm not going to play along if that occurs. I'm just telling you what I would do, what I have done, and my rotors have never fallen off. I've also never seen the need for new bolts unless you damage one. They are not torque-to-yield bolts.

 

Good advice I'll add to. Use a 24 oz. dead blow hammer on the impact driver.Polished the heads on a new set of stock bolts,I've had 2 reused bolts break and several come loose after good cleaning and red locktite tq'ed to spec.None since I started using new bolts.If you use heat use an electricians commercial heat gun. I've never had to use heat using the above methods.

 

Impact wrench will do the trick

 

All the replies had good advice, so if one don't work then try another. I've used both the heat gun and a torch. The torch has worked for me when the heat gun didn't. It also helps to hit it with a hammer while it's hot (if you can do that in that area).

 

Name brand quality tight torx and a cheap harbor freight 3/4 impact. Penetrant is a waste of time and effort with red loctite. Heat if you must as long as you control it. Quick and 500 degrees.

 

Torch in the wrong hands will flake chrome or make powder coats peel quickly.A "good" heat gun makes childs play out of even the HD factory thread locker which I've always found tougher to break and melt than Red locktite.Which ever method you use the biggest factor is the quality of the torx bit you use.It pays to buy a good set of torx and 12points fromSnap On,Matco,etc tool company. Good luck with your job kalamitty

 

Those Torx bolts are a major PITA. Last winter I changed my rotors and pulley. In doing so I busted, bent and twisted 7 or 8 various brands & qualities of Torx bits using anything from a leverage socket drive to pneumatic impact wrench. Use heat gun and penetration fluids as well.

I can't help thinking that there has to be a better way ...