[How to Tutorial] Fit or Adjust clutch cable – Hyosung GV125C GT125R GT250 GV250

[♠️ M77]

This quick tutorial will show you the correct way to adjust your clutch cable, so you reduce free play and keep your bike running smoothly.

Before you begin, make sure of the following:

✅ Clutch plates & springs checked within the last 4,000 miles (per service manual). Tutorial: Clutch Plate Replacement	✅ You’re using proper motorcycle oil (not car oil or cheap alternatives). Tutorial: Oil & Filter Change
✅ Cable is new and undamaged. Adjusting a damaged cable will cause it to snap sooner or later.	Need cables? Visit our shop – we keep them in stock.
❌ Don’t use “Chinese universal” lever holders. OEM Korean holders are the only safe option.	⚠️ Coloured Chinese levers will bend or flex. For safety, use OEM or Hyosung-approved XRT levers (only for GT250R & 650 models, not 125cc).

People sometimes say “my cheap parts are fine” — but when it fails mid-ride, it’s too late. Spend once, spend right. Especially for clutch & brakes.

Step 1

Install your new cable and route it correctly around the engine and frame. Connect it to your lever. (Skip if already installed.)

Step 2

Ensure the adjuster at the lever is screwed all the way in:

Step 3

Go behind the engine and remove the clutch arm:

Step 4

Re-install the clutch arm into the spindle. It should sit 1–5mm away from the sprocket cover. Align the “DASH” marking with the arm’s internal gap:

Step 5

Once aligned, tighten the clutch arm bolt to 10–15 ft.lbs.

⚠️ Always use a torque wrench — overtightening can damage components.

Step 6

At the lever, insert a spacer 2–3mm thick between the lever and perch (see photo). Don’t use credit cards!

Step 7

Slowly turn the adjuster out until you feel slight resistance — that’s the clutch beginning to engage.

Step 8

Remove the spacer and check operation:

• Squeeze lever 3×
• Check clutch arm moves smoothly at the engine
• Verify lever free-play is 2–4mm before engagement
• Reinstall the rubber dust cover

Final Check

• Warm up bike for 5 minutes before riding (v-twins need oil circulation).
• Do a short test ride before going far.

Common Questions

1. Lever feels wrong even when adjusted?
   – Wrong cable, stretched cable, weak springs, or worn clutch plates (replace).
2. Clutch lever vibrates at idle?
   – Re-check adjustment (steps 1–8). Arm or adjuster may be half-engaging clutch.
3. Bike cuts out when changing gears?
   – Faulty clutch switch (green + brown/black wires near airbox). Replace, don’t bypass.
   
   
   
4. Cable feels rough?
   – Check for fraying, re-grease, or replace. Avoid cheap holders/levers.

I hope this tutorial was helpful. Questions or improvements? Drop a comment below 👇❤

For other tech support (non-clutch), start a new topic here.

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