Forums 🚥 PIT STOP 🔧 Hyosung Technical Help [Tutorial] Hyosung GV/GT 125 & 250 Clutch Plates Replacement How To

This topic contains 2 replies, has 2 voices, and was last updated by  ♠️ MARCEL 8 months ago.

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  • #780

    ♠️ MARCEL
    Administrator
    Joined:
    Nov 30, 2017


    Learn how to change Hyosung GV/GT 125 & 250 Clutch Plates on the GV125 / 250 Engines (GT/GV)


    💥 NOTE! – SOAK YOUR CLUTCH PLATES IN OIL FOR 24HRS BEFORE DOING THIS! 💥 

     


    Tools needed :: Size 8-10 Spanner /  Stubby FLAT screw driver / Allen Key (if needed) / Oil Drain Pan / Size (15/17/19) socket/wrench for oil drain plug / mole grip (for the top oil filler cap) or socket for cnc plugs.

    Parts replaced :: Clutch Fibre Plates  (mandatory) / Clutch Bearing /  Steel Discs / Oil / Oil Filter

    Skill level = Anyone can do it, but if unsure, speak to a mechanic.  (Take this guide with your risk)


    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    • Symptoms / Back Stories ….
      Always replace your clutch plates when you notice the following:
    • every 5000 or 6000 miles. Regardless.  (just like “BRAKE PADS” have a wear limit!!)
    • when you see your self adjusting clutch line frequently.
    • when gears feel notchy / hard.
    • when bike slips up during gear changes.
    • Does your “Clutch” basket have any  “knocking” feel during idle ?
    • Does your bike “rumble” when you hold the clutch lever in ?  (Rarely)
    • not as fast as before (acceleration wise)
    • Clutch seems to “slip” on hard acceleration (What’s going on there?)
    • Let’s fix it….


      Technical Inspection  (What to look for inside…)
      HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    • Clutch Plate thickness LIMIT = 2.6mm  (New ones range from 3-4mm)
    • Clutch Spring FREE LENGTH LIMIT = 36.2mm  (Normal range is 3.8 to 4.6mm)
    • See ANY DEEP grooves on the CLUTCH BASKET?
      Time to replace it entirely!  – This applies to some bikes after 10K miles of their life regardless.
    • Silver Clutch plate discs (separators) – 1mm distortion limit.
    • Loud Rattling Sounds on the clutch cover?
      (your clutch plates have exploded or cracked in pieces)
      (Must replace them ASAP as these things will BLOCK oil passages inside!)

    Let’s begin!!!

    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    • Park your bike , get your tools out.  Start with the drain pan…. Drain Oil 1st…

    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    1. Get either “15mm / 17mm / 19mm” Socket , go under the bike and drain the oil.
      2. Clean the Oil PLUG!
      3. Once the oil is 100% drained.
      4. Fit the plug back inside.
      5. Tighten to a maximum of “15 Foot Pounds” (or 20 N.M) (Torque Wrench Value)
      If you don’t have a “Torque” wrench. Then just tighten your nut UNTIL you yourself know when it feels tight enough!🔥 BE WARNED! – THIS IS THE “DRAIN” PLUG  (DO NOT UNDO ANYTHING ELSE UNDER)
      HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB
    • Ready?  Get the NEW clutch plates / discs out…
      HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    In the blue circles , remove the engine cover bolts.
    Remember where each bolt goes! – Some of them vary in size.
    🔥Be warned! – OIL WILL SPILL OUT. (Left overs)

    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    When you reach the oil filter – Be warned, that the rod goes all the way in to the engine.
    So the quickest way to remove the rod safely is to:
    1. Put 2 nuts on top of each other.
    2. Undo the 2nd nut….    (the TOP #1 nut is a “stopper”)
    3. Undo the 2nd nut until the rod comes out entirely.

    🔥 Be warned – Some cases , a pair of mole grips can undo the stud with some force – but will leave scars!

    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB
    Don’t Lose the O-Rings!  (there 1 for the cap & 1 INSIDE the oil filter hole.)(2x rings.)
    It is always recommended to replace o-rings “whenever” there is an oil change job or clutch changes.

    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    Once all the bolts are removed….Use a stubby tool like a small screw driver…
    1. Go under the bike and tap slightly the “marker”  in the blue circle (LEFT PICTURE)
    2. Once the cover , splits –  Go to the TOP of the clutch cover.
    3. Near the oil cooler pipes , put the screwdriver or a blunt steel knife to twitch the cover (towards you)
    4. Now, we have some movement…
    5.  Remove the clutch cover!
    🔥 WARNING = The “gasket” must be removed and replaced with a new one. Regardless.
    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB


    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    Now your clutch system is exposed.  Get size 8 Spanner & take the bolts out…
    From top down….
    Undo — > Top Bolt 25% out  , Bottom Left 25% , Bottom Right 25%
    We now have 3 bolts undone slightly , now undo the rest 100% (take em out)
    Then remove the last 3 bolts – This method protects the clutch springs.


     

    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    • Remove: front clutch hub and investigate the parts below (inspection)
    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    #10 , 16 , 17 , 13


    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    Take out your plates one-by-one … this is very important…
    Remember the ORDER of each plate
    Hint: The last plate is always “Fibre”  & the FIRST plate is always “Fibre”
    Hint:  STEEL separaters go in between.
    Done?
    Use the SAME ORDER to fit your new plates!  Use the diagram below…

    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    Then –> #13 –> 17 – > 16 -> 9 -> 10 = This is the ORDER….


    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    It’s time to tighten it! – Remember start from the TOP 25% screwed in, then bottom left & right 25% each respectively.  Then maximum on the remaining 2.  The first x3 bolts , 100% also.

    This method is to apply equal pressure everywhere to protect the clutch springs.   Hyosung book’s also mention the criss-crossing star style of fastening bolts.

    WARNING! =  A CLUTCH BOLT IS HIGHLY SENSITIVE TO OVER TIGHTENING. – ALL CLUTCH BOLTS = MAX TORQUE 5 FT LBS  (FINGER TIGHT!)  

    Tighten with 2 fingers (that’s tight enough)

    HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

    • Last not , least – Close the clutch cover. Top up your bike with oil.Remember these points
    • MAX Torque for “all engine covers” – 5.5 ft.lbs  (It’s made of aluminium)
    • Required Oil = 2x 1L Bottles  (Fill up 1.6L of oil)
    • Use fresh :: Oil , O-Rings , Filter & Gasket.  
    • Record this event in a book somewhere or back of owners manual – This creates a log of your work & record mileage  (also proves how long each part lasts 😉 )

    Make sure your oil is marked 10w40/15w50 JASO MA2 ESTER – Nothing upsets these v twins than running crude oil , I’ve never seen so many BEARINGS in a small v twin! )- That tells you all you need to know – Good oil is a MUST. 

    See that clutch? Why are  you pouring oil through there first ? 😉   –

    🏁 Ride Safe!  Any questions hit me below!

     

    // Meditation doesn't mean you have to sit still....

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  • #1751

    mesaboogie
    Member
    • Topics: 1
    • Replies: 4
    Joined:
    Nov 30, 2017
    @john
    Location:
    Scotland
    Riding:
    GV125cn Cruiser
    Points: 67

    trying to remove clutch cover on my 125GV…………. Instructions say

    • 1. Go under the bike and tap slightly the “marker”  in the blue circle (LEFT

      • 2. Once the cover , splits –  Go to the TOP of the clutch cover.
        3. Near the oil cooler pipes , put the screwdriver or a blunt steel knife to twitch the cover (towards you)
        4. Now, we have some movement…
        5.  Remove the clutch cover!
        🔥 WARNING = The “gasket” must be removed and replaced with a new one. Regardless.

       

      PICTURE)HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

      Can anyone tell  me just where this is?…..under the bike?

      Thanks all!!

     

    • #1754

      ♠️ MARCEL
      Administrator
      • Topics: 31
      • Replies: 134
      Joined:
      Nov 30, 2017
      @mf448kxn6
      Location:
      North UK
      Riding:
      GTR
      Points: 1,896

      Hey,

       

      • Look at the blue arrows.   1 tab is at the top and 1 tab is under the bike  (under the clutch-cover should i say!)
      • Put a little screwdriver  “behind” the tabs, and then tap them so that the clutch cover can wedge / pop off!
      • Sometimes the “paper” gasket sticks hard, so the tabs help us use a mallet / rubber hammer etc… to tap the cover out of the bike.

       

      Hope this info helps…  Let me know!

      // Meditation doesn't mean you have to sit still....

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