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

Viewing 3 reply threads
  • Author
    Posts
    • #780
      ♠️ MARCEL
      Administrator
      • Topics: 38
      • Replies: 487
      Joined:
      Nov 30, 2017
      @mf448kxn6
      North UK
      GTR


      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 “O-Spanner” Stubby Flat Screwdriver Allen Keys
      (if needed)
      Oil DrainPan Size 15/17/19 Sockets Pliers or
      MoleGrips
      Rags Time Patience

      Optional 19mm socket/spanner for CNC Magnetic Oil Filler Cap

      🎁Parts Replaced ::

       Clutch Plates (fibre)  Clutch Bearing  Steel Clutch Discs
      Oil (1.5L)
      JASO MA2 Grade
      Oil Filter & O-Rings

      💪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 / Troubleshooting Hints …
      Always replace your clutch plates when you notice the following:

      • every 5000 – 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?
      • not as fast as before (acceleration wise)
      • Clutch seems to “slip” on hard acceleration

      🔧 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 13-20K miles of their life regardless.
        or if the damage is very minimal, gently file it until it’s smooth.
      • Silver Clutch Metal Discs (separators) – 1mm distortion limit.
      • Loud Rattling Sounds on the clutch cover?
        (your clutch plates *may* have cracked in pieces)
        (Must replace them ASAP as these things can block oil passages inside or worse!)
      • Clutch basket center nut must remail tight with its washer intact.

      🚦 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.
        A. Clean the Oil Drain Plug
        B. Once the oil is 100% drained.
        C. Fit the plug back inside.
        D. 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, left over oil will spill out!

      _
      _

      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.
      🔥 NOTE – in some cases , a pair of mole grips can undo the stud with some force – but it may scratch the bar!
      _
      _

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

      .

      .

      HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

      Once all the engine clutch cover 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 knife to twitch the cover (towards you)
      4. Now, we have some movement…
      5. Remove the clutch cover!

      .HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB
      🔥 NOTE! = The “gasket” must be removed and replaced with a new one
      (Sometimes old gaskets may tear off!)

      .
      .


      HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

      Now your clutch system is exposed.
      Get size 8 O-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 facia plate cover and investigate the parts below (just inspect them)
      HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

      Parts => #10 , #16 , #17 , #13 on this diagram above^ (Inspect those numbered parts)


      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 DISCS (Seperators) go in between.
      Done?
      ⚠ Use the SAME ORDER to fit your new plates!  Or use the diagram below…

      HYOSUNG GV 125 250 CLUTCH PLATES uk hysoung FORUM OWNERS CLUB

      Then fit back the other parts in the diagram above^
      These numbers are the parts in diagram above^ #13 => 17 => 16 => 9 => 10
      This is the ORDER of fitting them….


      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 (100%) on the remaining 2 => The first x3 bolts , 100% also.

      This method is to apply equal pressure everywhere to protect the clutch springs.   Hyosung books also mention the criss-cross star style of fastening bolts.

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

      A torque wrench really helps!
      or else Tighten with 2 fingers (and 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 below…

      • MAX Torque for “clutch engine cover boltd” – 5.5 ft.lbs
        (It’s made of aluminium)
      • 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

      👍 Recommendation = Make sure your oil is marked 10w40/10w50 JASO MA2 ESTER – Nothing upsets these v twins than running junk overhyped  (yes, over-hyped) castrol oil , (Many small parts in a hot small v twin!)- That tells you all you need to know – Good oil is a MUST.  Motul & Silkolene are best.

       

      🏍 Ride Safe!  Any questions hit the comments below!

       

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

    • #1751
      mesaboogie
      Member
      • Topics: 3
      • Replies: 5
      Joined:
      Nov 30, 2017
      @john
      Scotland
      GV125cn Cruiser

      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: 38
        • Replies: 487
        Joined:
        Nov 30, 2017
        @mf448kxn6
        North UK
        GTR

        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....

    • #4381
      Trevor
      Member
      • Topics: 6
      • Replies: 14
      Joined:
      Nov 30, 2017
      @bigtrev1969
      Lisburn
      Hiyosung Gv125 aquila

      Im having trouble after fitting new upgraded clutch on my hyosung gv 125cc aquila.

      When i go from neutral to 1st gear bike still feels its in neutral. Back wheel goes round a few times then stops and can move freely like neutral?

      All gears are the same like still in neutral.

      Regards Trevor

       

    • #4386
      Trevor
      Member
      • Topics: 6
      • Replies: 14
      Joined:
      Nov 30, 2017
      @bigtrev1969
      Lisburn
      Hiyosung Gv125 aquila

      All sorted and bike running beautiful. I had put the thrust bearing in wrong. Flat washer was meant to go on last behind the bearing washer.

      Anyways all running well and like a new bike with all these modifications over the last  2 years.

      I would definitely recommend putting a 520 chain kit and upgraded clutch in the bike.

      A big thanks to my pal Marcel for all the guidance over the last 2 years while i upgraded this hyosung 125 gv aquila. Its been a long journey but worth it all as bike looks and feels like new even tho its a 2007 bike. Only thing left to upgrade is the cooler to a 250cc cooler.

      Trevor

Viewing 3 reply threads
  • You must be logged in to reply to this topic.
Skip to toolbar