Suzuki GN250 Clutch Replacement

[@harrylime5147]

look at the clutch basket mate. Those tabs that stick up and index into the outer clutch basket, those tabs overtime beat grooves into the clutch basket. Your clutch basket has those grooves beat into them.. you need a new clutch basket. The problem with those grooves being where they are is, when you pull your clutch in, those fiber plates can’t separate as easily because their tabs have embedded themselves into grooves on the outer clutch basket. those grooves prevent the fiber tabs from moving freely in that slot designated for the tabs to stick up.This is a very common problem on Suzuki RM 125 motocross bikes from that era.. I had a 1989 RM 125. When I would be woods riding, in a tight section where I needed to work the clutch, or while stopping, I would pull the clutch in and it would not disengage most of the time because of those grooves that the fiber tabs wore into the clutch basket... I can plainly see those grooves worn into your clutch basket in this video. Watch the video look at the where on those clutch basket tabs in the 1 o’clock area of the basket.. every one of your slots on that outer clutch basket will look exactly the same.. the obviously larger piston and the extra weight of that with the rings and the wrist pin and wrist pin bearing weighing more than the 250 stuff. Did you notice more vibration? Because possibly the crankshaft for the 250 piston was counterbalanced to offset vibration, and that may not be the proper counterweight on the crankshaft for that size piston. this is critical because I remember this when I read it about 30 years ago. That a 10 ounce piston in an engine with a 50 mm stroke, at 10,000 RPM’s, that piston weighs approximately 2500 pounds to the wrist pin due to centrifugal force. I modified my Yamaha Road race machine, a Yamaha RD 350, and the clutch would slip due to the increased power. I took washers off of spark plugs and put them under the clutch springs. This increased the pressure on the clutch and eliminated the clutch slippage

[@Bobaine]

Thanks mate. Just gave my 250 a new clutch. This vid was good information.

[@markharris8718]

Your very welcome, stay safe.

[@thackleberry]

Thanks for the video, used this to sucessfully replace my gn250 clutch pack - like other have said, its more to give confience to do it - I had never done a clutch before - really appriciate it!

[@joeylegaspi3515]

Thank you for posting this! Just saved some money by doing clutch replacement myself.

[@marksgemfaceting]

Your most welcome

[@hugopereiramusic1]

Thanks for the video Mark! I am considering changing my gn250 cc into 300 and your videos are clarifying for my project. Look forward to see your video testing the motorcycle. Grtz from Belgium

[@SpyderTom1]

Thanks a lot for the upload, your did a very good job explaining things. I am doing my GZ250 this week end, you kept the guess work out. I instruct for a living and I am telling you it that is not what your doing, you should. Again, great job.

[@fritzsalander6361]

I'm about to do a GZ250 too. This video is great.

[@grandpabrogan]

Beautiful custom motorbike colour! So simple and yet so gorgeous!!

[@marksmaintenancehowto6727]

I don’t know for shore however they all work on the same principle, just take lots of photos with your phone as you dismantle, and then reverse the process at assembly. That has saved me many times.

[@markharris8718]

I am by no means a wiring expert, however just go on line and search gn250 wiring diagram. It’s a very simple setup and easy to follow. It will be best to get a cheep multimeter to trace the wiring. Good luck.

[@tresaqui07]

Thank you for video i’m thinking of replacing the clutch on my G250 this will help me heaps.

[@ngadiminsrowot5399]

Thank you, Mark.. now i can replace the clutch plate by myself.. 🙂

[@markharris8718]

Thanks for your interest, I did not notice any extra vibration all works well together, however I am no judge of this as I only gave it a quick road test before I carried out the work.

[@niallburnside7227]

Great video Mark, really clear and concise. I have a GN250 so will store this one for later ;) I have a questions though .. the bolt on the outside of the clutch cover, what is it? The one towards the front, just below middle. Cheers Buddy. N

[@marksgemfaceting]

Hurray, you've got it.

[@MrHyltonL]

Thank you for such a detailed and perfect video you are awesome. Thanks so much.

[@marksgemfaceting]

Your very welcome I enjoyed the project. Thanks for watching.

[@chaist94]

Aaargh! I only remember putting ONE little ring on before i put the clutch back together. No wonder it won’t go in to gear. Better try that one again. Cheers.

[@marksgemfaceting]

Always the way, keep trying it’s the way to learn, good luck.

[@chaist94]

@@marksgemfaceting the good news is that the big bore upgrade went perfectly, the engine started right up, timing and valves were spot on. New timing chain is nice and quiet. The clutch will be an easy fix.

[@chaist94]

It wasn't the ring washer, that was in there, I forgot to adjust the clutch release screw. it was too loose for the new clutch plates to engage. Once it was screwed out a couple of turns it works fine.

[@brasszippo]

thanks very much for a very helpful and informative video,, doing my clutch this week, so yeah cheers mate.

[@marksgemfaceting]

Your welcome and good luck

[@alfrides4373]

Congrats on a very well put and detailed video. Thanks for sharing. Best wishes and greetings from Mexico City! Alf

[@marksgemfaceting]

Your welcome. Wish I was in Mexico City, the weather in the UK is very damp and grey at the moment. Stay safe

[@VictorGarcia-uz5gd]

Good video thanks for the info and 😂 I lost it when you called your wife

[@marksgemfaceting]

Thanks for watching

[@petergrove5132]

Thank you for the video. About to tackle this job tomorrow.

[@markharris8718]

Peter Grove Your very welcome enjoy the job.

[@snatr]

Lucky guy having a mate like Karen 😉 Thanks for the info 👍

[@markharris8718]

Thanks for your comment I told Karen she had a fan, she is very pleased and sends her regards.

[@snatr]

@@markharris8718 Thanks! Stay safe over there guys 🙂

[@stephen3224]

You can carefully dress those burs off of the clutch basket with a small and fine file I did fix an old 1970s gt that way just remove tho obvious burs and it will work fine always fit brand new clutch plates and clutch springsbwhen rebuilding any engine band bre pair born replace the clutch pushrodbif at all possible

[@Thatuptownguy]

Mark I have a GN250 engine off an older motorcycle on my dune buggy. Im looking to see if I could email you a few photos and if you could help me with the ignition system wiring. Thank you.

[@erzhureghfsghreswfhjte3569]

Good work! Can you please tell me how many Nm are the little screws holding the cover?

[@skip-intro]

Hey Mark! I noticed you have an aftermarket exhaust installed. I’d like to install one myself. Do you have a link to it? Or do you have a recommendation finding one that fits the diameter of the exhaust pipe?

[@MikePaulsen-b3c]

Could you help me get my GN125 running smoothly please?

[@argirisgalanis812]

Thank you for the video ,very good information,congratulations

[@markharris8718]

Thanks for your comments and good luck this weekend with the job.

[@cilaptrcili]

hi mark can you get us a link for spare parts

[@markharris8718]

Greetings to you from Portishead, England.

[@prajolkansakar2937]

Can abs be installed in gn 250

[@adrianador]

nice txh 4 video was loking 4 one in pasth but was no info or data about 300cc update let us know how is the acceleration or power increase... did you jet the carb?

[@davidweinberg3290]

Amazing video ,gave me confidence to change mine , what size drive socket do I need to remove the case ?

[@markharris8718]

Hi David, it’s dark at the moment I seem to remember that it was a 8mm for outside case.

[@davidweinberg3290]

@@markharris8718 thank you so much

[@zafarijaz1991]

You can provide clutch plates.?

[@marksgemfaceting]

Your very welcome, Good luck.

[@HughBrown-w1x]

Good video well taught.Thankyou

[@marksgemfaceting]

Thanks for your kind words

[@markharris8718]

Your very welcome. Will do another one when funds allow.

[@philsheppard8521]

Hi Mark, thanks for the informative video. I followed it to a tee this evening. All went smoothly. Except now the bike won’t let me change gear. I can pull the clutch and that disengages as it should only I can’t move the gear pedal. Any ideas what I did wrong? Thanks in advance.

[@ponsonbylad]

might have jammed your change linkage, ive done that sometimes we you move things around, take the engine cover back off and make sure the gear change fork is moving freely

[@yeetenman]

Did you have to adjust the carb to compensate for bigger bore?

[@marksgemfaceting]

All I did was up the jet size and a normal tune

[@ismailasasfeh2106]

Pleas ,How can i change Lamp break Suzuki gz 2006 ?

[@ismailasasfeh2106]

Dear Very nice Thanks too much

[@marksgemfaceting]

You are very welcome

[@ismailasasfeh2106]

Good morning How can i change lamb light break “ Suzuki gz 250 model 2006 ?

[@ismailasasfeh2106]

Please Sent to me video

[@markharris8718]

Thanks for watching, and I hope you enjoy doing the job. Let us know how you get on.

[@JacobVaughan]

Can you clarify how you adjust that centre nut? How much movement should there be?

[@marksgemfaceting]

If you are talking about the clutch adjustment nut screw it in until it touches then back off a quarter to half turn good luck

[@sickrreaclown7209]

Greatings from Ecuador

[@alfonsojimenez2097]

Hola buenas tardes soy de México y me gustaría un vídeo cambio de retenes del piñón de arranque palanca de velocidades y del eje de embrague gracias

[@ishmaelfien7016]

Very grateful for the tips. Can anyone help me out on how to replace Suzuki Tu 250cc clutch push rod

[@marksgemfaceting]

@@ishmaelfien7016 sorry I sold the bike good luck.

[@gradyking4186]

Great video!

[@mrsam225]

great videos

[@markharris8718]

Thanks your welcome

[@mingli6327]

can you still ride it on road legally ?

[@marksgemfaceting]

Yes I declared the bigger cc to my insurance it was only about another twenty pounds to insure.

[@marksmaintenancehowto6727]

Your very welcome

[@yavuzkaya632]

Thanks, I love you

[@markharris8718]

Your welcome.

[@วิทวัสสุขสวัสดิ์]

I have a suzuki volty250cc.

[@marksgemfaceting]

That’s the modern version of what I had, nice bike.

[@altairlucio3375]

🤔👍🇧🇷

[@marksgemfaceting]

Your welcome