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I would leave it alone. That tab helps to keep it in place from your boots tugging on it.
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Sounds like you are missing the exhaust guard that was mounted to it.
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You `re a glutton for punishment! Good luck.
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Actually heffergm, ask about the original Jack. He had the first light spring made for the Pro clutch.
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I waited and no replies. Depends on elevation, but one step bigger pilot might work.
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MRS445001213 9 tooth straight from the GAS Gas parts book. Now to find one!
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You would need custom made spokes, just on the hub side. It can be done. Just won`t be very cheap. You could use the stock Yamaha spokes on almost any Excel 36 hole rims or the old style tubeless 36 hole from a gas gas, etc.
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The Aprilia had the chain on the rh side. Looks like they flipped the tire around and flipped the swingarm upside down.
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Just clean up the rust, but that caliper sure looks funny upside down!
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Heat the brakes good by running up and down the street with the brake on. Throw a bucket of water on the caliper. If done right, they should steam. And I`m not joking.
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Digger has the right idea. Just like a hydraulic clutch on a car. Remove the whole assembly. Hang the caliper at the top. Forget the hardware, push the piston with a Phillips screwdriver. Best if you had a meter of clear hosed attached to the bleeder held above the caliper to watch the progress. Good luck. Ps. put something between the pads to simulate the disc.
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You have to remove the dust seal and then the clip underneath. Put the lower leg in a vice and it will pull apart, but it takes a lot of force.
PS. Screw the cap back on to do this, but just finger tight.
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Do you have free play at the lever? You must have a loose feeling between the lever and master cylinder. At 10mm it should not slip. Are you using a proper gasket? You cannot just use silicone for a gasket.
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https://www.youtube.com/watch?v=rDFm1L3kDHY
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I`m old school, no shield. I think some smoker hater came up with the shield idea.
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They need to include a half dozen with every new bike. 3 for the front 3 for the back. If we have to suffer with this crap, the manufactures should be up front about this.
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The 7mm head was the upgrade. Originally they had 3mm allen heads which had to be knocked loose with a chisel. You could of saved all that sanding just by burning that clutch in. Fourth gear against a tree and give her hell. Test, and give it another good burn. 5 minute job. Some of us have been doing this for thirteen years. Nothing new.
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Getting up this ledge requires a good quick clutch. This bike has always had the gm auto trak 2 in it since new. 12 years and the engine has never been touched. Almost a record for a Pro motor.
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They changed the color, the frame geometry, and the air box. And maybe the CDI. Which means almost nothing in the manual. 2004 had the most changes for the Rev 3`s
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Actually the factory came up with ATF. Jim and Dale were using GM auto trac 2, the blue stuff at 15 bucks a quart. Which worked better than anything. Then all of a sudden it was ATF only. That 75 wt makes the clutch lethargic. Trials riders have used atf for decades. Just wait till you actually have to work on this beast!
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Pretty simple, 75wt will lube it fine. But ATF will make the clutch work. Remember to change often as it`s the transmission oil on the Pro that lubes the mains. Not the two stroke mix.
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The 300 sounds like a street bike. Just quit doing wheelies and nobody would look.
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The clamps are re-usable time and again. The gassers have been pushing coolant since `94.
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The little black circle just pops out from the front, but could break the tab due to age. Sounds like a cracked frame. Had a 2002 with several.
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Some Showa`s died along the way. Hard to get a replacement bladder etc. No telling what previous owners could of done.
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