Helping a friend with his new to him 200? Road King. We are servicing the bike completely, I don't think the oil has been changed since the Bush administration. One of the (rusty) spark plugs was loose finger tight. Ugh! I'm too old for this sh*t, but I said I'd help.

Big problem is that the derby cover bolts are the original crappy Torx, and froze solid. I've never had a bolt stand up too long to my trusty hammer impact tool, but these aren't budging. I've drilled or chiseled individual bolts out in the past, but I think it will be a PITA to do all of them. Any techniques I'm missing and should try first?

 

Removing just the head of the bolts with a drill could get the cover off. With any luck after the cover is off the bolts might screw out easier.

A left hand drill bit can produce good results also.

The chisel will probably destroy the head of the bolt before coming loose.
If they won't hold up to the proper tool they'll probably die to a chisel. At least that's been my experience.

 

Left hand drill bits. See if you can find a store for machinist's supplies, most hardware stores don't have em.

That said, if you drill with regular bits and take off the tops of those bolts, do all of em, there should be a bit of the bolt sticking out. Heat that with a propane torch or a BIG soldering iron, then do em with a vice grip.

someone probably used thread locker sometime in the past. I use anti-seize (the gray graphite like stuff) and don't turn em in TOO tight.

 

If you drill off the head (and the others came loose), you should have enough to grab with vice grips. maybe.

 

Good ideas all. I'll look for the LH drill bits, but out here in the sticks if Home Depot doesn't have it, it's mail order.

 

If you are talking the type of impact you hit with a hammer you might try an actual impact wrench, air or electric. I am having good luck with these lately.

 

I would try a small easy out first before drilling heads off.

 

You're a good friend, I hope he's supplying the beer!

I've had a good impact screwdriver (hammer type) that works just about every time. But mine only has flat and Phillips.

 

Penetrating oil, drill, and ez out.

 

Those are pretty small I'd just drill 'em. Drill the heads out...derby will fall off...now you got just the little shafts left in there, can try with grips, or continue drilling. I'd guess too small for ez-outs.