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[RedDevil]

Even with the auto tensioner - having the inspection cover is an easy way to pour the oil in without spilling it all over the primary

You're right.  I wish they hadn't removed the inspection cover....

  

[Twolanerider]

Even with the auto tensioner - having the inspection cover is an easy way to pour the oil in without spilling it all over the primary

With the hydraulic clutch it's the only hole I ever open up.

[grc]

Got that and use it.  

I do not like how tight these are...they should not be impossible to remove...but I will try the impact driver...and new screws everytime.

No need for new screws every time Bill.  Don't use loctite, torque the screws to spec (I believe it is still 96 in-lb), and they will break loose for the next change without any drama.  I have to believe that the person who did your 1k service either used a heavy duty thread adhesive, or more likely just tightened until they squealed rather than use a torque wrench. 

Jerry

[BIGDOG]

If these have been Loc Tited take a heat gun and heat them up. Loc Tite will soften and release at 300 degres. You may need to run the engine so you aren't fighting the counter sink effect.

[Travelinshoes]

I dislike the Torx screws.  Whenever I take them out for any reason I replace them with hexheads.  Probably to don't look as good, but I think more user friendly.

T

[Twolanerider]

You're right.  I wish they hadn't removed the inspection cover....

  

Was actually surprised they did that.  It's very unMoco-like to remove an accessory item they can sell for $$.

[WFP]

Thanks All...stopping at Sears tonight for the impact Driver.

Nothing was on the threads of these screws although there was some white stuff on the oil and tranny drain screws (teflon?) I put new o-rings on those but no teflon when re-installed.

Will need at least two new ones so i will get 5 anyway.

i will not use loctite...

/Bill

[MUFFMAN]

Same thing happened to mine when I went to chrome screws. Chrome actually heats up & bonds itself to the other metal when it heats up. I ended up drilling & using "Easy outs" to grip what was left & get out. Now I always use thread ease(anti-seaze) on all fasteners of this type include plugs before fastening. It Doesn't allow the one metal to bond to the other while still keeping it tight. THE MUFFMAN

[Texas 103]

Five screws?  So the derby cover rather than the service cover?  In either case no reason any of those should ever have been that tight.  They're just 1/4" bolts after all.

The WD-40 won't help from the outside.  Can't penetrate to the threads.  If the socket head of the bolt is rounded out beyond use only a couple of things come to mind.  There are some easy out tools that will sometimes grab on rounded out screws.  It's a crap shoot but worth a shot.  Craftsman has some made to grab an internal socket head or Phillips screw.

Other idea that comes to mind is just that; an idea.  I don't know if the screws come through far enough to protrude on the inside.  If they do, and if they do enough, might pull off the primary cover and grab the other end with a pair of vice graps to break them loose.

And if everything else fails.. EZ-OUT to the rescue 

[Spike]

Same thing happened to me earlier this year when I was changing fluids. After the the torqx head stripped and I couldn't get it out with an easy out type tool, I took my dremel tool with a cutting wheel after the bolt. First I knocked the cutting wheel down to a smaller diameter so I wouldn't do any damage to the derby cover, then I just cut a flathead screwdriver notch in the head of the bolt. Still took some muscle but it came right out.

[AXIL]

   chrome screw +chrome primary cover + moisture +condensation =corrosion/the other loctite.  use antiseze.                                                                     axil

[SERK3]

WFP, SAMETHING HAPPENED TO ME, ROUNDED THEM OFF, BROKE TWO EASY OUTS AND DRILL BITS, FINALLY THE SHADE TREE IN ME CAME OUT, TOOK A SMALL FLT HEAD SCREW DRIVER AND HAMMER AND STARTED TAPPING UNTIL THEY BROKE LOOSE, IT TOOK ME LESS TIME TO GET THE LAST THREE OUT THAN IT DID THE FIRST TWO. I REMOVED ONE AT A TIME AND REPLACED THEM WITH THE BLACK ALLEN HEAD BOLTS THAT CAME WITH THE CHROME TOPPERS.

SERK3

[HogBreath]

If a good Torx bit breaks off, What is the chance for an easy out to get the fastener out? That's usually when I have a broken drill bit, & an easy out broken off in there. 

[hdbrad03]

MOCO Engineering I feel caused the issue. We use to screw the Torx screw directly into the Aluminum Outer Primary. Now I think harley is using steel inserts driven into the Primay. Maybe the bolts are reacting with inserts??? 

 
Brad

[AXIL]

hdbrad03, moco engineering ? there are no steel inserts. please explain your post as i don't get it. i say it is still techs causing the promblem as my earler post say.   axil