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Author Topic: 08' GT250 clutch problem and question  (Read 1615 times)

WoofTheCat

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08' GT250 clutch problem and question
« on: April 29, 2017, 02:02:02 PM »

Hey everyone.

I've purchased a 2008 GT250 Comet last year around fall, it's already a fuel injected modell. Anyways, it wasn't working, the rear cylinder was completely trashed. Bought the new parts, my dad put it together (worry not, he is a car mechanic, things can't go that wrong). The engine is now seems to be flawless, but the bike has some bad clutch issues.
When I took it to a test ride, I couldn't shift up to 2nd gear. Took it back home, we've adjusted the cable. Now I was able to shift up properly, but in 3rd gear and over 50 km/h the clutch slipped, rpm skyrocketed and the bike slowed down. So I downshifted, turned around and tried to get home. After about 500 meters, in 2nd gear and at 45 km/h the clutch slipped again, and I had to downshift once again. We did another adjustment, but it didn't really change a thing, so we took it apart, turned out the springs are below the service limit.
I've already ordered a new set of springs, they are on their way. On the other hand, my dad suspects that the springs alone couldn't cause this. The driver and driven plates also got measured, they are fine and reach the standard limit.

So my question would be: What else should we look for?
Also, can somebody please tell me the correct number of driver and driven plates? I think currently there are 5 driver and 4 driven plates in the clutch basket. I've tried searching for an answer with no luck so far. Some diagrams show 5-4, yet sets are being sold as 6 driver and 5 driven, and I'm confused.

Let me know if you need any more information, and any help is appreciated.
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Dagra82

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Re: 08' GT250 clutch problem and question
« Reply #1 on: April 29, 2017, 08:21:18 PM »

1.- The clutch has metal separators. The metal separators have a rounded shape on one side of the separator and on the other side is tapered.
You have to remember the face or the lada with the rounded shape has to go towards the engine and the cutting or sharp side out.
2.- Look at the clutch hub and you can see that the clutch discs have hit it and it has an endidure. If the hub of the clutch has an endidura will give you problems and will not let open the clutch well.You have to clean the slits and leave it smooth

3.- Clean and grease the clutch cable. When clean the clutch cable leaves a separation of 1 or 2 millimeters.



sube
You mount the metal separators well, the clutch discs and if you still note that you must be very tight the clutch cable or the gears go very hard you can do something else, but with caution.

Loosen the lock nut and then tighten the screw 1/4 turn and test.


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WoofTheCat

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Re: 08' GT250 clutch problem and question
« Reply #2 on: May 01, 2017, 07:26:57 PM »

1.- The clutch has metal separators. The metal separators have a rounded shape on one side of the separator and on the other side is tapered.
You have to remember the face or the lada with the rounded shape has to go towards the engine and the cutting or sharp side out.
By driven plate, I meant the metal separators. They are in a good condition and they were mounted well.


2.- Look at the clutch hub and you can see that the clutch discs have hit it and it has an endidure. If the hub of the clutch has an endidura will give you problems and will not let open the clutch well.You have to clean the slits and leave it smooth
The clutch hub/basket is in good condition as well, there are no damages or any signs of wear.


3.- Clean and grease the clutch cable. When clean the clutch cable leaves a separation of 1 or 2 millimeters.
Taking a look at the cable is a good idea. I'll note it and try not to forget when I'm at home.


You mount the metal separators well, the clutch discs and if you still note that you must be very tight the clutch cable or the gears go very hard you can do something else, but with caution.
Loosen the lock nut and then tighten the screw 1/4 turn and test.
Let's hope there won't be any need for that.


I'm still open for ideas because it'll probably take another 2 weeks for the springs to arrive (thanks to customs......).
And I still need an answer regarding the number of driver/friction and driven/metal plates.
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umop-ǝpisdn

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Re: 08' GT250 clutch problem and question
« Reply #3 on: May 01, 2017, 09:58:52 PM »

The workshop manual would tell you how many of each of the plates there are.

http://hyosung.hu/download/pdf/data/service-manual/gt250-125%20carburetor%20service%20manual.rar
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WoofTheCat

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Re: 08' GT250 clutch problem and question
« Reply #4 on: May 02, 2017, 11:49:25 AM »

The workshop manual would tell you how many of each of the plates there are.

http://hyosung.hu/download/pdf/data/service-manual/gt250-125%20carburetor%20service%20manual.rar

Thank you for the answer, but unless I'm blind, it does not contain the number of plates. You see, I even have this manual in Hungarian, and I've read it over and over again. I also searched for and downloaded a service manual for the carby and the extension for fi models, but non of them had the answer (unless I missed it, but I can assure you that I've read the parts regarding to clutches several times, used pdf readers with search functions trying to find "friction", "plate", "clutch", "driven", "driver", and non of them had the results I needed).

Not to mention that the service manual (on page 80) has a picture with the correct order of driver and driven plates, BUT it won't tell the number of them. We have a webshop for ordering, and it has diagrams of the parts (here), and as you can see, it's 5 and 4 of them. Now the service manual picture has 6 and 5, and sets are being sold as that - hence the confusion that I can't wrap my head around. I bought this bike as it was not working, and a service where the previous owner brought it, took it apart months before the purchase. Some parts were missing when we also took it apart, and I'd be damn mad if they removed 1 driver and driven plate.

EDIT: Just to top the confusion that I have, I've also checked the GV250's clutch diagram, and it has the same product number for the clutch hub but it shows 6 driver - 5 driven plates. Why would the GT need less if it's the same hub?
« Last Edit: May 02, 2017, 01:08:24 PM by WoofTheCat »
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umop-ǝpisdn

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Re: 08' GT250 clutch problem and question
« Reply #5 on: May 02, 2017, 08:55:22 PM »

They are exactly the same engine and to my knowledge the clutch is identical! Good thinking to check the GV manual.
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Cloud

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Re: 08' GT250 clutch problem and question
« Reply #6 on: May 02, 2017, 08:59:07 PM »


Someone put car oil in.
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WoofTheCat

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Re: 08' GT250 clutch problem and question
« Reply #7 on: June 30, 2017, 01:27:33 PM »

An update on this:
Ordered a new clutch kit, and installed it, as we could not indentify the problem.

Took it to a test ride today, and the bike won't accelerate in 3rd and 4th gear. 5th seems to be working fine.

When the engine was rebuilt, the transmission gears didn't seem to be worn out, but we will probably take it appart again. Any ideas what to look for? Anything else that can cause this?

Edit:
Some clarification because my English skills suck.
Shifting up to 3rd gear for the first time was alright and then the rpm skyrocketed with no acceleration. Probably jumping out of gear? 3rd and 4th gear currently are acting like neutral. I think it also slipped (or jumped) out of 2nd gear once at a higher speed.
Anything I can do to confirm or refute that the gears are worn out without taking it completely appart first? (I don't know, like shifting up and keeping my foot under the gearshift lever would make any difference?)
« Last Edit: June 30, 2017, 10:00:46 PM by WoofTheCat »
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WoofTheCat

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Re: 08' GT250 clutch problem and question
« Reply #8 on: July 11, 2017, 06:53:19 PM »

Another update:

Took the engine appart. It seems somehow the cam stopper plate shifted a bit while putting the engine together for the first time, and it broke (pic here). Everything else was in perfect condition. So I guess this was causing the trouble...?

It seems this plate has the "25381-45400" part number, which also happens to be the Suzuki's cam stopper plate part number. Does anybody know if I can purchase the Suzuki one? Will it fit?
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umop-ǝpisdn

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Re: 08' GT250 clutch problem and question
« Reply #9 on: July 11, 2017, 08:40:31 PM »

Woof,

I doubt that anyone has done it before, but my understanding is that the GV250 and the VL250 share a lot of parts.
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