Reply To: [How to Tutorial] Clutch Plates Upgrade Replacement for Hyosung GT GV125 GT250R GT125R GV250
I’d been experiencing clutch problems with my GV 250 for a while. When the engine wasn’t running, the gears shifted smoothly, but once the engine was running, shifting became extremely difficult.
I removed the clutch plates and measured their thickness. The platens on the clutch basket had left slight marks, so I lightly sanded them to prevent them from binding.
After reassembling the system, I observed that when I squeezed the lever, the outermost platen separated from the basket, but the clutch plate and plates stuck together and didn’t separate.
I removed the plates and plates again, cleaned them thoroughly with brake pad spray, and dried them. I placed a glass window on the table and placed 240-grit sandpaper on the glass. I laid the clutch plates horizontally on the sandpaper and slowly sanded both surfaces.
The clutch plates were 2.9 mm thick. I cleaned and dried them again with brake pad spray and compressed air.
I also lightly sanded the clutch metal sheets using the same method with 400-grit sandpaper. My goal was to reduce the vacuum and sticking effect between the plates and the sheets.
I reassembled the system, added oil, and started the engine. The gears are much smoother than before. I’m happy with it so far, and I wanted to let anyone know if they’re experiencing similar issues.
One more thing:
It was quite difficult to find neutral between 1st and 2nd gears. I wanted to remove and check the neutral cam stopper shaft and spring. When I removed the plug, I found the spring was missing.
I think someone thought it was an oil plug during a previous oil change, removed it, drained the oil, and forgot to put the spring back. I installed a suitable spring, and now 1N and 2N gears are perfect.