Clutch removal

[eamartin]

1-Will the left exhaust need to be removed to remove the left side case?
2-I anticipate the need of an impact tool to break loose the case screws. Some of the case screws are recessed a bit. How do I break these loose without scratching the case paint?

Thanks, Angel

[mike1969]

You will have to remove left side exhaust. Impact driver should work unless the screw heads are stripped. I had to drill the heads off of some screws the boogered badly.

[Repsol]

As stated above you will need to remove the left exhaust and if I remember correctly the foot peg and shifter. I had to use an impact driver to get the screws out of mine. I bought a set of allen bolts off of Ebay so the next time should be a bit easier. It's a pretty easy job once you get in there. Good luck.

[conbs]

Remember that ALL of the screws on your 305 are Japanese Industrial Standard. While the thread pitch is different from modern metric sizes for 3, 4, 5 and 12 mm screws/bolts, the screw heads are ALL JIS. They look like Phillips but, if you use a Phillips bit/screwdriver you will probably "cam out" the head of your screws. You will then be drilling them out.

Allen heads are one solution. But, you will save yourself a lot of time and frustration getting the old ones out by just getting yourself a set of JIS screwdrivers or bits. You will likely not need new screws either, if you do. Vessel tools sells them.

I just noticed Retro Bikes in Port Angeles WA is closing up shop. They have been selling complete sets of case screws for 250/305 for $20. They ARE JIS head screws. I am pretty sure I have seen other vendors selling the same sets on ebay.

I hope that helps.