I was trying to remove the upper belt guard on my 2009 Nightster, and have managed to strip the Torx bolt that is holding it on. I still haven't been able to remove the bolt or nut. I'm going to try to drill the bolt out, but I was wondering what size bolt I will need to replace it. I would like to replace it with something other than a Torx bolt. Help would be greatly appreciated.

 

the lower bolt? just get a new one from the dealer.

 

Get official part from the dealer

Lower bolt
4354 (I'm guessing this is the hamfisted part)

Upper bolt
3880

Im not sure how to help you get ruined bolt out

 

Might try to find one off an earlier Sportster, my '91 has a regular hex head bolt for the lower shock mount.

Left side bolt: 3958
Right side bolt: 4743
Not sure why they are different numbers, maybe one shorter than another.

Probably just have to drill the other one out, just start small and go to increasingly larger bits till you can take the head off.

John

 

I'd say on your way to the dealer to get a new screw, stop by the hardware store and get you a proper torx bit or socket

how the hell did you strip it? using a flathead screwdriver?

 

At 45-50 lbs/ft, of tightening it may make a bigger mess to go up in bit size but a 2 sets of torx bits (sae /metric) should be about $20 at habor freight or a tool store. Couldn't hurt to try and then have the right tools on the next go round

 

Start hittin' it with penetrating oil. You'll be glad you did, once you get the head drilled off and attempt twisting out the remaining stud with Vise-Grips.

 

It's still just a bolt and a nut on the bottom, correct? If you drill off the head, you can just pull the headless bolt and nut from the wheel side, while pulling the shock on its side. Unless it bolts into the swingarm itself now?

John

 

It's been a while. I think you're right about the nut and bolt. I was thinking the swing-arm was threaded.

 

Thanks for all the advice guys. I was using the right size torx bit, T50. The thing is so tight it seems impossible to get off. It is a torx bolt on the outside, and a nut on the backside. I'm not sure if the arms is threaded or not. I still haven't had any luck getting it off. I guess the next step will be to try and get the head off and see if I can pull it through the backside.