Ok, I'm putting the last of the Christmas presents on my girlfriends '08 Nightster and damn if I can get the clutch inspection cover off. The screws are all torx and a T-25 is a tad too small and a T-30 is too big. Using the 25, it wants to round out the inside. Had anyone had any issues pulling the cover off and what did you use?

 

T27 and nothing else. Use the right size tools & good quality.

 

+1! Get a good set of bits. a T27 is the correct size for this. Hopfully you haven't already rounded out your torx bolts..

 

+1 Bingo.

 

Good-lookin RK, bet it sounds great with those Rhineharts too.

 

Like everyone else said, T-27. If you already stripped the bolts, you can drill the head off with a bit and pop the cover off, and then use a vice grip to twist them out. They go into blind holes and have a fair amount sticking out of the primary with the derby cover off and no heads on the bolts. Then replace them with hex heads because they're so much easier to get on/off.

 

when you get that derby cover off Please throw those damn torx bolts away and get some allen head bolts much better than torx and also dont loose the spring behind cover

 

Torx are fine if you have proper tools. I've seen allens round off too.

 

Roger that! Usually after I drill them, haven't yet got the Derby off w/o drilling, the rest normally come out be finger.. no vice grips needed. Allens are the way to go IMHO.

 

A T-27?? Crap!! My Craftsman kit goes by increments of 5, hence the 25 too small and 30 too large. Apparently my Torx kit isn't the complete kit. Trust me, I am EXTREMELY **** about the quality of my tools, BUT I can't afford Snap-On .

FORTUNATELY I know when to stop and I did not round off anything. The fit JUST didn't look right, so I stopped there.

Thank you everyone sooo much! I'm not a **** when it comes to these things. I'm very mechanically inclined but this was pissing me off. I've never not had the right tool for something and if a project comes up where I need a tool, I JUMP on it!

Looks like I'm adding to the Torx collection tomorrow.

Thanks again!!!