The new rotor bolts come with a coating. Don't know what the coating is, but I'm **** enough to follow HD's instructions to the letter, especially when it pertains to brakes.
Also, the rotors will have a minimum thickness spec inscribed in them near the center, so you may want to mic the thickness if the bike has some mileage on it.
My feeling is that the head is a torx head and they tend to get chewed up on removal. the factory puts them on tight as hell. I would use a breaker bar and some heat. The white stuff is probably a low grade locktite. I would use red loctite.
I changed my rotors and re-used the old bolts with no problems. I asked a Harley dealer service manager about this and he said there is not a problem re-using your old bolts.
I changed my rotors and re-used the old bolts with no problems. I asked a Harley dealer service manager about this and he said there is not a problem re-using your old bolts.
When I had my D407 replaced with the D408, the HD Dealer used new rotor bolts because that's what HD recommends. They also replaced the rotor bolts on my back wheel when they checked the wheel for sand in the bearings.
In my opinion, if the bolts come off without damaging the heads, I don't see an issue with reusing them after applying Red Loc-Tite to their threads.
But if I was putting on polished rotors, I would use chrome rotor bolts.
using a d/a sander would work great. not sure of the grit, but 240 or finer should be okay. that is if you have access to a d/a sander, it's an oscillating round padded head sander that runs off of air. easiest way i can think of anyway.