I've had enough
 

I replaced the torx bolts on my primary derby cover with Allen stainless steel bolts. I started to remove the primary derby cover to chagne the oil and another Torx bolt stripped. I'm pretty careful because those suckers strip so easily, but this one was last done by the dealership at the 1000 hr.

After drilling out the bolt to get the cover off, I went to Ace to get the Allen bolts. I hope they perform better, they sure can't do any worse.

They look better too.

Beary

I hear you. Same situation here with the stripped head from the dealer. Easy-Outs can save you big time!

I just did the same. I want to slap the guy that approved torx for the primary cover.

Be careful with the stainless as they are soft. I use them to hold my baffles in and have to replace them every other time since the heads don't like the soot on the threads...

Your derby cover bolts shouldn't be all that tight. If they are then the tech is not allowing for the oil on the threads and reducing his torque to compensate. If they're so d@mn tight you're stripping the heads then the gasket is being crushed and I'm surprised it's not leaking. Are you using a 25 or 27 torx?

I use 25, 27 Torx, and 25, 27 Torx+. As the bolts get worn, I find the one that gives me the tightest fit. I've been very careful on my 09 and have had no problem with the T27. In this case, the bolt was way over tightened and partically stripped when I got to it. I am going try out the Stainless bolts and if they don't work, I will try chrome. But I've drilled out my last torx on the derby cover.

Beary

The torque applied to the bolt should be reduced by 15-25% if there is oil in or on the threads.

If the head strips, i.e. not the threads of the bolt, you can get them off quite easily by positioning a small chisel or punch at the 10 o'clock position on the head and strike downwards with a small hammer. That forces the bolt to move in a CCW direction and in every case for me has come off easily. That said, I've also gone the Allen route and haven't had to remove them yet. Ace has chrome bolts for $2 each (1/4 x 20 x 5/8").

I had the same problem when I got the bike from the dealer. I replaced them all with Chrome bolts from ACE hardware store. Looks great and have no problems removing them for service.

I've done that as well, but I'm kind of clumsy and get nervous hitting sharp objects with a hammer near the bright shinny chrome cover. :) I used to be an aircraft mechanic and got pretty good at drilling out rivits, so drilling off the head only takes me about five minutes.

Funny, I would have bought the chrome bolts if I could have found an ACE employee to unlock their chrome bolts bin. Ace really watches that chrome stuff.

Beary

The torx bolts on the derby cover are T27. Most of the time people put a T25 on it and that starts the strip out cycle. Like everyone else, I replaced mine with stainless buttonhead screws and put a dab of anti-sieze on them as it's stainless against aluminum and there is a nice chance for galling there. I check them for tightness whenever I clean the bike and have not had one need tightening yet