[009jim]

hi Folks, I've been doing quite a bit of research since discovering I cannot budge the derby cover screws on my Sporty. I understand it's a common issue. After trying the easy way with a T27 bit and a normal wrench and getting nowhere, I have devised two possible ways to move forward. I've bought a 1/2" square to adapt my T27 impact bits to both these tools described below.

1. Use my rattle gun. This is a standard air driven rattle gun like used in a tire shop to change wheels on a car. As I understand it the impact action of this machine is torque only. I could also reduce the air pressure to the gun to perhaps give more control.

2. Use my old impact driver. This is the type that you hit with a hammer and it simultaneously results in force inwards and rotation torque.

I'll try to upload photos. Which do you think is the better approach?

 

[009jim]

I'm generally opposed to hitting cast aluminum parts with a hammer , but Lisle sells a neat little impact driver just for 1/4in hex bits.

Can you find me a link to that? I looked but can only find 1/2 inch drive.

 

[009jim]

If all else fail drill the head off carefully once cover is off it will often comes out real easy.

Some reports I've read contradict this. There is only 1/4" of the screw to grip and if it was loktited in you are in trouble.

 

[009jim]

The best tool to remove those screws, is a high quality 3/8" drive, T27 socket,, in an air powered 3/8" impact wrench, like an ingersol.

Is there any tendency for the driver to cam-out? You'd obviously need to use body weight to keep up solid inward pressure on the tool?

 

[009jim]

If you work on your bike much you'll find an air impact driver one of the best investments you'll ever make. In the old days a lot of the fasteners were phillips head -- what a nightmare trying to remove without buggering the head. Bought a hammer type impact driver that served me well for years, but hard to reach some fasteners. The air impact driver pretty well solved that. Now I have 3 different sizes depending on the job.

Not sure exactly what this is. Can you please post a photo or link. Is it like this one?

 

[009jim]

You haven't been fukin' around with that screw for a week have you?
Just wack it with a hammer driver and be done with it.

I only just got the T27 impact bits in the post mid-week, and I work all day. Prolly give it a whack this Sunday. There's 6 screws. Four are in good shape, one is a bit gnarly and the 6th will be a problem coz some dumbass has already had a T25 in it and minced it somewhat.

 

[009jim]

hi Folks. I used my impact driver on one of the screws today. This is the result:-
1. driver bit twisted slightly.
2. screw head now mangled.
3. screw never even moved a fraction.

 

[009jim]

Was that an air or hammer driver?

YEP..........hammer type. I have an air driven "rattle gun" but it is rated too high and I'm sure it would have jumped out because there is no axial force, only torque.

 

[009jim]

Damn.... you'd think force from the hammer would drive that bit deep into the screw to avoid slipping like that.

Have a closer look at the photo of the screw head. There was no slip, the torsional force has yielded the internal lugs.

 

[009jim]

All of the 6 screws are stuck. One was butchered by the owner(s) before me and I have butchered one with my efforts. Not going to butcher them all. I'm exercising patience because right now the bike can still be ridden. The moment I drill the head off I'm committed and will not be able to shift the bike without a trailer. Still pondering my next move.

 

[009jim]

Did you get the little bastards out?

My brother owns a HD workshop and has a good mechanic with a lot of experience with these screws, so I'm gonna drop it to him when I get some time. Am considering replacing with black steel Allen head cap-screws and never-seize on threads. Will ask him to keep the old screws so I can draw conclusions about there being loctited or not.

 

[009jim]

Did you get the little bastards out?

Asked my brother to look at it last week. They said they were not difficult to remove. No drilling necessary. Used an impact driver just like mine. I am totally confused as to why I couldn't get them out.

Some of you are probably going to suggest that I had the impact driver wrong way, but that's not it because you can see from the deformation of the bit that I was doing it right.

Anyway, at least the problem is solved.

I have put the OEM standard screws back in but I want to replace with hex-socket-head-cap-screws (not button heads). Can anyone give me a link to where I can get them online as I have no suitable supplier near me.

 

[009jim]

I have put the OEM standard screws back in but I want to replace with hex-socket-head-cap-screws (not button heads). Can anyone give me a link to where I can get them online as I have no suitable supplier near me.

Edit: - Harley part #3594 is it. Maybe I can get from the dealer.