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

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

@marksgemfaceting

2 ай бұрын

Your most welcome

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

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

@markharris8718

4 жыл бұрын

Your very welcome, stay safe.

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!

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

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

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.

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

Жыл бұрын

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

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.

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

@markharris8718

4 жыл бұрын

Peter Grove Your very welcome enjoy the job.

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.

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

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

@marksgemfaceting

2 жыл бұрын

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

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

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

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

@marksgemfaceting

2 жыл бұрын

Your welcome and good luck

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

Thank you for the video ,very good information,congratulations

Greatings from Ecuador

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

@marksgemfaceting

2 жыл бұрын

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

Hurray, you've got it.

Greetings to you from Portishead, England.

@prajolkansakar2937

3 жыл бұрын

Can abs be installed in gn 250

Great video!

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

Your very welcome, Good luck.

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

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

Thank you, really enjoyed the clear and informative video,all the way it is presented and easy manner, thank you.l look forward to more videos, also learning.Thanks my friend.

@marksgemfaceting

Жыл бұрын

You are very welcome

Thanks your welcome

great videos

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?

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

@markharris8718

3 жыл бұрын

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

@snatr

3 жыл бұрын

@@markharris8718 Thanks! Stay safe over there guys 🙂

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

@marksgemfaceting

8 ай бұрын

Thanks for watching

Thanks, I love you

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

11 ай бұрын

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

@chaist94

11 ай бұрын

@@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

11 ай бұрын

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.

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?

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.

Your very welcome

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

2 жыл бұрын

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

Could you help me get my GN125 running smoothly please?

Your welcome.

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

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

@markharris8718

4 жыл бұрын

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

@davidweinberg3290

4 жыл бұрын

@@markharris8718 thank you so much

You can provide clutch plates.?

hi mark can you get us a link for spare parts

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

Dear Very nice Thanks too much

@marksgemfaceting

Жыл бұрын

You are very welcome

@ismailasasfeh2106

Жыл бұрын

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

@ismailasasfeh2106

Жыл бұрын

Please Sent to me video

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

@marksgemfaceting

Жыл бұрын

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

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

@marksgemfaceting

2 жыл бұрын

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

🤔👍🇧🇷

@marksgemfaceting

Жыл бұрын

Your welcome

I have a suzuki volty250cc.

@marksgemfaceting

2 жыл бұрын

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

can you still ride it on road legally ?

@marksgemfaceting

2 жыл бұрын

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