So I performed the 5k service on my Sportster the other week and had a hell of a time getting the derby cover bolts off to adjust the clutch. i ended up having to use an extractor on 3 of them. This was after I purchased a new T27 bit. I then headed up to the dealer for new bolts and as soon as I started using the torque wrench I can feel the new bolts about to strip again.

I figured the next time i will replace all the bolts with a different type of metal but I am unsure what type. Any suggestions on replacing the stock bolts with stronger ones that at the very least can withstand the recommended torque?

 

The first time I removed the derby cover torx screws, I replaced them with SS button head hex (allen) screws. Most Ace hardware stores carry them.

 

How much torque are you using to secure them? Are you stripping the heads of the bolts or are the threads in the case (now) damaged?

Once they are incorrectly overtightened (or cross threaded) it means the threads are stripped. You can't simply put in another bolt to cure the matter. You may need inserts which replace the damaged threads, and the matching bolts for the resized thread inserts.

 

No, just the heads are stripping. The service manual says 84-108lb. I set the wrench to 85lb. Someone else suggested going stainless. Why does HD not ship with stainless steal bolts in the first place?

 

You do know that's INCH/lbs and not foot/lbs, right?

 

My pappy taught me way back in the pre internet days to give it a few light taps at the end of your removing tool to kinda unseat the threads. You dont need to hammer them, just a few taps. Never had a problem with removing nuts bolts or screws doing that before removal. Seafoam deep creep soaked into rusty nuts and bolts when needed, then tap.

 

Yes, inch/lbs.

 

Something tells me this is the problem!!!!

 

[QUOTE=cHarley;12985919]The first time I removed the derby cover torx screws, I replaced them with SS button head hex (allen) screws. /QUOTE]

I finally got sick of them too, and replaced with the same, stainless steel allen head.

 

Big yes to replacing derby cover torx with allen head bolts. And do not use any sort of thread locker. Believe it or not I have found that before.

Simply snug them up by hand then tighten to the lowest noted torque reference. No need for cranking those puppies down.