I'm a new Harley owner. I have an 1999 883 Sportster. The clutch cable is leaking oil. I purchased a new one while I was in Oregon. I went to replace the cable this weekend and I assume I need to remove the circular cover with the 4 Torx screws to set the pulley in the clutch. I can't get the Torx screws out. Any ideas?
Thanks,
Don

 

Do a search on derby covers and Torx screws and you will find sympathy and a number of solutions, from penetrating oil, rapping the screw, drilling out, extractors, etc., depending on how futzed it is.

My own method is to use a chisel or sharpened screw driver to cut a slot at the 9 o'clock position, then take a fine punch and rap it downward at the edge.

Re the oil leak. It may be an overfilled primary or a leaking seal, although I am not that familiar with a 1999. Suggest a Clymer manual, which will come in handy.

 

Much appreciated. Let you know how it goes.
Thanks.

 

Make sure you have the proper size torx bit. Many torx bit sets do not contain the #27 bit. Also, pickup a hand impact tool for the bit. You can find them in most auto parts stores. I would try that first before I started grinding and chiseling on the screws.

 

Just hit the same problem here last week.

Just to save you the aggravation of the search feature...

I took someone's advice from here and drilled of the HEADS ONLY". Pop the cover off and the screws for me turned out by hand/finger. Must get just enough bend in the cover to lock 'er on for good.
Anywho, ran to the hardware and picked up stainless allen heads to replace.

TORX BLOWS!!!!!
Who ever invented those dammm things should be hung by the "boys" along with the same azz-monkey who still manufactures staight head screws!!![sm=headbang.gif]

Best of luck

 

I agree with cHarley. Sometimes while putting some twist pressure on them and then giving them a wack with a hammer (small hammer!!), they'll break loose. But those damn torx do strip easily.

 

Agree with the hand impact tool for a first try. In my case it didn't work as the screws were beyond redemption when I got the bike. Beating on the tool against the derby cover also gave me second thoughts...I just knew I would break something.

 

Thanks all. I ended up having to drill all of the f*@! Torx. I could only get 3 of 4 out. Given that the bike is 9 years old and had some thin spots where the derby gasket goes, I purchased a new primary. Anyone have any tips (i've ordered a Clymer manual) on how to remove the clutch cable. I've given it as much free play as possible and for the life of me...can't get the nipple out of the clutch plate.

Thanks again.

 

I would try loosening the clutch adjustment to max. I am sure you already loosened the cable adjustment and removed the end from the clutch handle?