Trying to remove the rotors on my '05 RG, and one bolt is like STUCK! I've broken 6 T40 bits trying to get it out (Northern and Sears have been understanding), and I'm afraid I'll end up rounding out the bolt. Any suggestions? Bigger hammer? More power..hohohohohohoho?

 

Maybe it has locktite red on it? Hit it with a torch then go at it with a breaker bar.

 

Try an impact driver. Usually a couple of taps on the end of that will free up just about anything. They are cheap and last forever. You may want to first insert your torx screwdriver/bit into the bolt and wrap it a few times with a BFH. You do not want to break that bolt off. I had to weld a bolt onto one that was broken and it was tough to do without damaging the fork lower. The benefit was that the heat probably loosened it up for me because it turned right out.

 

heat yes, watch the torch might effect the bearings, a heat gun or the tip of a soldering gun, i had the same thing, 3 were soooo stuck, 2 came out, the last one took patience and a left hand drill to get the head off very slowly. good luck!

 

Was there any signs of Loctite on the other bolts?
I would try the heat gun route.

 

My $.02

Get 2 new bits.

Heat one of the bits with a propane torch till it's hot.

Insert the hot bit into the screw to heat it. Realize you will ruin the bit doing this.

Let it cool, then use the other new bit to remove it.

 

I tried an impact driver once when I had this same problem, Torx do not hold up well to that at all. It sheared the tip right off. In my case it apparently did crack it loose a bit though as I was able to get it off with a breaker bar and new bit after that. Try the heat idea offered by the others here, hitting it with a small propane handheld torch should do the trick. Try keeping the heat focused on the fastener and off the fork leg. The idea is to get the fastener to expand enough to break its bond, so you want to try and limit the heat to only the fastener.