Several of the bolts holding clutch inspection cover on are stripped. What is the best size drill bit to use to cut the heads off so I can replace them with allen head bolts?

 

I forgot to say its an 07 road king

 

Use an impact screw driver and a larger torx bit
http://www.harborfreight.com/impact-...ase-37530.html

 

I think those are 1/4-20's.The major dia. would be about .250".
I would work my way up to a 1/4".

 

Forgot to add that some have drilled off just the heads and then used vice grips in them after the cover was off.

 

Yep, I did the same thing. Then I went to Lowes and replaced them with Allen head screws.

 

It pays to use the correct sized Torx. This is a common mistake people make. Use one size too small, strip out the heads, and there you go.

 

Do not drill the bolt to 1/4",that is the outside diamiter of the bolt. For 1/4" tap, the drill size is 13/64, 1/64 over 3/16.

When you say clutch inspection cover, are you referring to the cover on the left with 5 torx head bolts?

I would ( very carefully) use a center punch on the outside diameter of the head of the bolt and drive the bolt loose.

BTW, I'm not sure those bolts are even 1/4".

 

I used easy outs and drilled them out and bought new ones to put in.

 

Over the years that I've worked on my bikes, I've used torx-plus wrenches and have not had a problem with striped heads. Also apply a lot of pressure inward on the bolt when tring to brake it loose.