[Tutorial] Clutch Plates replacement on GV125S EVO 2022 (How to Upgrade)

[TomaszG81]

Bike Model = : GV125S EVO 2022 - Aquila 125 S

hi All,

I just replaced the clutch plates provided by Marcel on my GV125S Evo.

Link to the upgrade: https://hyoriders.club/shop/service-maintenance/upgrade-heavy-duty-clutch-plates-friction-drive-hyosung-gv125s/

I decided to document the tutorial, as I snapped one bolt during the process. Hopefully it will be useful for some of you, if you decide to do that job too.

1.  Start with disconnecting the clutch arm/cable

2. Remove the cover and be careful with the rubber seal so you don’t damage it. Note that two bolts are longer. I have a habit to place the removed parts in the same layout so it’s much easier to put them back later on…

3. Soak your new plates in clean oil, at least 4 hours prior installing them

4. Before unbolting the clutch basket, I did a small mark regarding old plates alignment

5. Unbolt the basket

6. and remove the plates

7. All plates are the same thickness. It’s important to remember that you start and finish with the clutch plates. In between metal disc goes in. There is only one important thing: metal disc/plate has one side which is sharper. Always install all discs with sharper side to the back.

8. new plates installed:

9. Time for bearing. Also important here, the bearing is not equal on both sides. Pay attention how the old one is positioned and install the new one in the same orientation.

10. Clean/replace the washer. Also remember that the washer goes first, then the bearing (basket->washer->bearing)

11. Time to put the basket back, new springs and old (??) bolts. Remember to torque the bolts back in the criss-cross pattern, slowly and equally. Hyosung manual says to torque them for 6-10Nm. And this is the moment where I failed:

and to be honest I do not know what happened. I’m not completely newbie in the mechanics (I restored my Corvette c4 by myself including engine) so I suspect that the old bolts were already tired. When I torqued them by hand until I felt resistance, I took torque wrench and set 6Nm. All five bolts got 6Nm. Then I put 7Nm and it took me one full turn to get into 7Nm. Here I should already stop as normally it takes one quarter to get 1Nm. I continued and two full turns to get a click at 8Nm. I made four bolts and fifth snapped….

First I thought it’s because of stiffer springs from Marcel but of course I was wrong. I suspect it’s because of original, cheap and soft bolts. I used new bolts, 5M16mm and reused old washers. This time all went perfect. First 6NM, then one quarter to get 7 and then 8. All perfect, using same wrench.

12. Time to put the cover back and re-set the clutch cable/tension. I didn’t record it but here is a nice video which will help you (8th minute and further):

13. Job done. Enjoy the stiffer and more punchy feeling. I personally love it. Highly recommend to do that, especially if you see that your oil is a bit grey. This means that the clutch plates are getting worn and time for the change.

Thanks and I hope it’s going to be helpful.

Cheers,

Tomasz

[♠️ MARCEL]

Beautiful tutorial!!!! Very well explained there sir 💖🚀👍

I will link this to the product page so it gets more coverage.

It is a good shout about the bolts , maybe i will get some stronger ones and stock them too just incase other riders need it too.

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