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The only Torx bits I have ever broken were T45 trying to break brake rotors loose. I've broken Snap-On, Cornwell, Craftsman and, Harbor Freight T45s using everything from a 3/8" ratchet to a 3/8" breaker bar to a 1'2" drive breaker bar....conclusion: Those freakin' bolts are TIGHT!
I can also say out of all the brands mentioned above I have never bought a set of Torx bits that did NOT include a T27.
Derby covers, inspection covers and brake and clutch lever brackets are all T27. Primary drain plugs that use Torx are T40. Switch covers are T25.
Like most here, I have never seen a Torx+ on any Harley application.
Many HD bolts are actually Torx Plus, which is shaped slightly different and runs a bit oversized. So a "T27" might in fact be a T25P.
Torx will go into a TP and appear to fit but be loose enough to cause stripping. TP won't go into a torx, so its easy to tell which you have. I always try my TP first and only if it won't fit do I go for the Torx. But on my 07 and 09 nearly everything is TP. On the 2000 it seems some are Torx and some TP, but the latter could have been changed by a PO. I don't know when HD switched (but I do know they call everything "Torx" in their service manuals).
Oh, and the derby is actually T25P (torx plus). A T25 wobbles like a 90 year old man, a T27 still has play, but a T25P fits perfectly.
Sears sells a nice set of SK Torx Plus which include a T27P and they're having a sale today if you order online.
Harley uses Torx Plus. Common mistake, lots of guys have trouble with using wrong size on derby cover.
HARLEY DOES NOT USE TORX PLUS!
There was a long thread about that earlier this year and a whole bunch of people went out and bought torx plus sets only to find they did not fit much of anything on the bike. I can't find the actual thread but here is a thread in response to it.
The biggest mistake being made is using a T25 when you need a T27. Get a good quality set, I bought a whole set of Snap On Torx, metric hex and standard hex in a blow molded case on ebay for $150 that were just like new, money well spent. An impact driver you strike with a hammer like the one in Mud's post is also a great tool for Torx, hex or even phillips or straight machine screws.
Last edited by iamrfixit; Aug 28, 2010 at 08:30 PM.
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