CLUTCH WILL NOT RELEASE

[LOUD MOUSE]

Oil is in the left side case.
Last time a feller had this he didn't have a kick lever installed and the rear gears would rotate until they locked with the front set.
Are ya installing the cover after ya have twisted the Kick Starter shaft clockwise to stop and made sure the lever and spring are installed correctly?. ......lm

OK, i took the cover off and cleaned out the hole and there was the ball. Used nice fresh grease and put it all back together. I guess the next step is get some brake cleaner and clean everything up, verify no metal plates are warped and clean up the surfaces on the metal plates.

Here comes a silly (and probably stupid) question. There is supposed to be oil inside this cover, right? This is the first time I ever had it off.

Stan

[sjptak]

YEA!!!!

Thanks to your responses here and in past posts (especially I-man's from November of last year) my problem is no more. I took the clutch apart including the metal and fibre plates behind the retaining wires (or as the parts manual calls them, the Ring, clutch plate stopper). I laid them out in the same order I pulled them off. I used a very fine grit steel wool on both sides of the metal plates, removing any surface contamination. Then I cleaned each of the metal plates with brake cleaner, using the air compressor to dry them off and hopefully blowing off any leftover "grit" from the steel wool. I slammed it all back together, put both covers on, shifted to first gear and the wheel was locked. Pulled back the clutch lever and now the rear wheel spins with only the slightest bit of drag. Thanks to all the knowledgeable 305 riders out there, when I get it all back together, I'm going for a ride tonite!!!!

Now, the last question I have. Since I leave on the 27th for a 7 month trek without the bike, what precautions should I take before I store it? As I said earlier, I used this as a daily driver until I put it up for 2 years. I didn't expect a froze up clutch. Should I take the clutch plates out and let them sit in an oil bath while I'm gone? Should I just say screw it 'cause now I'm an expert and can take the left side down blindfolded? It almost looks like either way, I'll be taking it apart again.

What say ye, knowledgeable Knights of the Vintage Dream?

Stan
The guy who gets to ride tonite

[paperslammer]

Hey - just taking my clutch apart while I have the left side casing off. I see that you sanded down the metal plates in between the rough plates...is it OK to light sand the rough plates - or would be a terrible idea? I see a little bit of buildup on the rough plates, but would that make the clutch not catch as well? Thanks for any thoughts!

[e3steve]

Now, the last question I have. Since I leave on the 27th for a 7 month trek without the bike, what precautions should I take before I store it? As I said earlier, I used this as a daily driver until I put it up for 2 years. I didn't expect a froze up clutch. Should I take the clutch plates out and let them sit in an oil bath while I'm gone? Should I just say screw it 'cause now I'm an expert and can take the left side down blindfolded? It almost looks like either way, I'll be taking it apart again.

What say ye, knowledgeable Knights of the Vintage Dream?

Stan
The guy who gets to ride tonite

Congratulations, Stan! What a buzz, eh?

In such a position, with regard to leaving the bike standing for seven months, I would:

• Almost fill the tank
  Pour about 200cc of oil into the tank and rock the bike from side to side a few times
  Run the motor up to temp then drain the oil
  Remove, empty, clean, WD40 then refit the carb float bowl
  Tywrap the clutch lever to the grip to separate the clutch plates for the duration

Seven months isn't exactly a "dry storage" period, but it's already been stood for a couple of years so such precautions should alleviate clutch or gas problems.

[dlobby12]

I'm having the same trouble with may 305 ca77. I don't see a ball bearing in the parts manual, is there one for this bike, and if so where can I get a new one.

[dlobby12]

I'm having the same trouble with may 305 ca77. I don't see a ball bearing in the parts manual, is there one for this bike, and if so where can I get a new one.

[e3steve]

I'm having the same trouble with may 305 ca77. I don't see a ball bearing in the parts manual, is there one for this bike, and if so where can I get a new one.

Most bicycle shops should have one. It's a number 10 (5/16" -- 8mm). Here's a montage of the clutch system; item 34, far right(ish):