I just got a 2002 super glide I can't get the screws off the round primary cover the one to check and fill lube oil . Is that a allen head or a trox head and what size is it? Its looks like they might be stripped and I can't tell what kind of head was on them. To get the outter primary cover off do I just take the foot peg and gear shifter and the outter bolts off will the outter cover come off then.. Then mabey I can get the round cover off . Thanks Frankster69

 

It's called the derby cover. Don't ask me what the hell a derby is in relation to a motorcycle's clutch. The bolts are torx #27. They're bad about rounding out too. Best to use a good socket. If you've already stripped them, get a good sharp drill bit just a tad bigger than the bolt's threads and drill the heads out. Keep it lubed and be careful. Once the heads are off there is no more tension on the threads. No need to remove the outer primary cover to get the bolts out.

 

Good advice here make sure you use a #27 torx socket. A #25 will fit in there and round them off. Follow the above instructions but DO NOT remove the primary case. In any case it might be a good idea to replace them with new torx screws or allen head screws. But my best advice is to get a service manual for your bike. Try Zanotti's HD in Butler Pa. website...(google them). You should be able to get the manual for $40-45. Good luck!

 

Case in point:

I thought I'd be slick and slap on my new black finned derby cover this morning before heading off to work. I pulled out my #27 and, for the life of me, I couldn't get the thing to fit the head. So what did I do? I used #25 and - g**d***it! - I stripped one!!! [:@]

Luckily, I think I was able to get the three I had loosened back on tight enough to get me by, however, I'm baffled. I just don't see how the #27 fits. I'm a little leary about drilling out the bolt on my own. I've never done it before and I'm afraid I may leave shavings in the primary or something. I'm thinking about taking it in, having them drill it out, slap on my new derby cover and replace the bolts with allen heads. I'm pissed to say the least.

Whiff

 

Sears has some new stripped bolt/screw removers.

http://www.sears.com/sr/javasr/produ...id=00952154000

 

They work like crap on Torx screws......

You need to use a T-27 socket with a hand impact to break them loose... NOT AN IMPACT GUN... Hand Held, Hammer/Mallet operated Impact Driver....

Once you get them out, coat the threads with anti-sieze....

 

I stopped by the dealer on the way home from work and picked up the allen replacements. I'm going to attempt a drill out on which ever ones I can't remove. Seriously though, if the #27 is the correct size, I don't see how if fits. You gotta bang that thing in there, I guess.

Whiff

 

I was a little uneasy about drilling them out too, at first. Use a sharp, high quality bit just a little bigger than the screw threads. Can't tell you what size I used because I've got a big set of over 200bits including wire gauge sizes and don't remember which I used. Keep the bit wet with spray lube. Once the head pops off, the rest will just screw right out.

 

Just to emphasize my mechanical disabilities, I would have never thought about lubricating while I drill [no puns intended there]. I really should've taken shop in high school.

Whiff

 

That's to keep the bit from either dulling out or burning up. As far as I know these are still Grade 8 bolts, not the easiest thing to drill through. Be sure to use something like WD-40 and not Astroglide! [sm=nothatway.gif]