westnile Posted August 24, 2011 Report Share Posted August 24, 2011 03 gg 280pro cant break the little bolts loose on the clutch to get the plates apart. The little allen wrench is just wanting to strip the heads. Do I need to heat them with a torch or something? Any ideas or is this a common thing? Could be too late for one, I may already have to drill it out and replace it. Just hope I don't have to do all of them that way. Thanks Quote Link to comment Share on other sites More sharing options...
lineaway Posted August 24, 2011 Report Share Posted August 24, 2011 If you are talking about the bolts on the spring, just use a small chisel to loosen. Then buy the 7mm head replacements used on the newer bikes. Quite simple. If you are in a huury use the chisel to re-install. Quote Link to comment Share on other sites More sharing options...
lineaway Posted August 24, 2011 Report Share Posted August 24, 2011 If you are talking about the bolts on the spring, just use a small chisel to loosen. Then buy the 7mm head replacements used on the newer bikes. Quite simple. If you are in a hurry use the chisel to re-install. Quote Link to comment Share on other sites More sharing options...
westnile Posted August 24, 2011 Author Report Share Posted August 24, 2011 If you are talking about the bolts on the spring, just use a small chisel to loosen. Then buy the 7mm head replacements used on the newer bikes. Quite simple. If you are in a hurry use the chisel to re-install. These little guys... Is that the spring? If so, how can a small chisel loosen them? Please explain a little more. And if I can swap them for a larger size head then that sounds like a must do. Thanks Quote Link to comment Share on other sites More sharing options...
lowbrow Posted August 24, 2011 Report Share Posted August 24, 2011 If you don't like the chisel approach to remove those that won't budge use a hacksaw to cut a slot for a regular screwdriver. You'll be throwing them all away anyway as the later hex bolt replacements are much better. Quote Link to comment Share on other sites More sharing options...
lineaway Posted August 24, 2011 Report Share Posted August 24, 2011 Just tap the exposed edge of the bolt to loosen. Quote Link to comment Share on other sites More sharing options...
jse Posted August 24, 2011 Report Share Posted August 24, 2011 These little guys... Is that the spring? If so, how can a small chisel loosen them? Please explain a little more. And if I can swap them for a larger size head then that sounds like a must do. Thanks That large, cone-shaped washer is the spring that exerts pressure on the plates. Another trick for taking out the screws is to use a good quality T-15 Torx bit tapped into the top and used as an "eazyout". Get the 10 replacement screws from your dealer and you will need a 7mm 12-point socket to install them. Don't overtighten them as the star shape acts as a kind of lockwasher. I wouldn't use any other screw than the GasGas ones as this is a critical area and clearance is an issue. Jon Quote Link to comment Share on other sites More sharing options...
charliechitlins Posted August 25, 2011 Report Share Posted August 25, 2011 Just tap the exposed edge of the bolt to loosen. Yup...put pressure on them with an allen wrench, then tap them with a hammer where the washer-looking part sticks out over the fingers. I don't know why this works, but it does. Quote Link to comment Share on other sites More sharing options...
westnile Posted August 25, 2011 Author Report Share Posted August 25, 2011 thanks for the info... Ended up getting all out but three by using another allen wrench that was brand new. The other three were round wholes and stripped out. So I drilled and used the ez-out. Two came out, the third broke the ez-out. Well you can't drill those suckers out. So I grabbed the hacksaw and went at it. Thankfully that did the trick and I got it out. Now I'm just waiting on the new screws to show up. They told me that there is only one screw specified for it now and it is the newer 7mm. So I don't think you could replace with the old style even if you wanted to. What fun, this should have taken me no time at all, now it's taking days to get back going again. The previous owner removed the bleeder banjo bolt and replaced it with a standard banjo bolt at the hydrolic line. I don't know how he bled it that way, but I noticed that wasn't right and was able to order the correct one and have it coming as well. Hopefully things will be straightened out here and I can actually get a ride on this machine. Again, thanks for information Quote Link to comment Share on other sites More sharing options...
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