De-restriction – throttle derestricting GV650

[Owen]

Bike Model = : GV650s - GV650 efi

I’ve decided this needs a place online as i can only find vague mentions of it anywhere.

*NOTICE- This mod will remove the LAMS/learners approved status of the bike if disclosed or found out by the authorities.

I’ve got the 2016 Gv650S Aquila pro and its restricted from factory for LAMS approval in Australia and learner restrictions in other countries. They do this by stopping how far the butterflies open in the throttle, by means of a plate tack-welded to the plate holding the cables in place.

*Tools needed here ↓ are PH3 screwdriver, and a 4mm hex (allen key).*

1.  To remove the restriction you need to take off the plastics on the left side of the bike (the screws are circled in red) to reveal the throttle bodies (big red circle).

1.5. optional step- you can use 1 zip tie to move the coolant hose up and out of the way. makes it much easier to get your hands and tools in there.

*Tools needed here ↓ are 12mm open end spanner. Optional- paint pen*

2. Now that we can access the throttle bodies. Trace where the throttle cables go to and undo the nuts (on the end of the cable) holding them in place. You don’t need to remove the cables completely, just detach from the plate. Optional- put a small dot of paint pen on the nut/thread to make re-installing easier.

*Tools needed here ↓ are PH3 screwdriver, and a T-25 security torx key*

3. Undo the one torx screw on the plate, and the one phillips screw (both circled in green). You now have the plate that needs modding.

*Tools needed here ↓ are a choice for you. I used a dremmel, with a small cutting disk for the external one, and a small (8mm) cylindrical grinding stone. i cleanned up with a 2nd cut flat file and the grinding stone already mentioned.*

4. Now that you have the plate, you will see 2 tack welds holding the 2 plates together (circled in yellow). these need to be cut back/removed, so the plates can be separated. be careful not to bend the plates. also be careful not to damage the part circled in blue, this is the new throttle stop. clean up any parts that have burrs.

*Tools needed here ↓ are torque wrench that has a range from 0Nm -25Nm. OR just tighten by feel, i leave this choice to you.*

5. Re-install the plate, there are no torque settings provided by Hyosung, but the torque setting for M6 into cast aluminum is 5-7.9Nm. i went to 5Nm and then used a straight screwdriver and nipped it by hand.

6. Re-install the throttle cables. If you used a paint pen and put a dot, just try to realign where it was in the past. Otherwise at this point you will need to tighten/loosen the nuts up and down the cable to get the right feel in the throttle grip. i suggest getting this right before re-installing the body plastics.

7. Re-install the body plastics and your finished.

You will now be able to pull the throttle to wide open. It does make a huge difference.

I have also modded my throttle grip to a 1/2 turn throttle. This makes it feel like its still restricted at the throttle but still has the ability to go WOT. I personally don’t suggest doing this if you are new to riding, the throttle is much more sensitive to slight movements, and it removes the throttle return cable. I did this because I have a wrist injury from jumping 44stairs on my bmx… I’m left with very limited movement in my wrist and cant go WOT without regripping.

I’ll post up about the 1/2 turn throttle as soon as i take it apart again to take some photos.

 

Thanks for your time, I hope this helps some people out there trying to find info.

 

 

 

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