GZ250 Clutch replaced, difficult or easy?

[dougdftw]

The shifting on my '01 GZ250 is quite difficult plus it does not always disengage smoothly. The clutch cable seems to be adjusted correctly.

Am I looking at a clutch replacement? How difficult is that? I have some experience working on engines. (I just disassembled the carb on my Shadow 600 and cleaned out the jets and it even works better now). I do have the official shop manual for this 250 but in reading it it is the presumed the reader has more experience than I have. What special tool are required?

I figure this could be a good winter project. Any recommendations are appreciated.

Doug

[DrBob]

While I have never done a clutch on a gz250, I have done dozens on other Japanese, British, and American bikes. It only takes about an hour or so, and if you are just changing the clutch plates, springs, and/ or throwout bearing you don't need any special tools.

[Easy Rider]

Originally Posted by dougdftw

Am I looking at a clutch replacement?

Maybe not. What you describe is the clutch dragging. That is not usually a symptom of a worn out clutch..........which is kind of the opposite, it slips.

[dougdftw]

Thanks for the input.

I checked more carefully and find that the shifting is always difficult. This is really my major complaint. I also have a VTX600 and that shifts with a much easier action. There have been times when the 250 would not go into first unless I first let out the clutch in neutral and roll the bike 6 inches or a foot.

The other issue is not one of clutch slippage but rather one of a bit of a clunk - usually when first engaging mostly first gear but I have also heard it in other gears. Almost like something isn't firmly attached to it's shaft when it should be. It doesn't always happen - maybe one out of 10 times of releasing the clutch. The other 9 times the clutch engages very smoothly.

There is also bit of extra noise from the transmission. Sort of a constant chugging or grinding sound - even when sitting at idle in neutral.

I rode one of these models during the MSF last May and don't remember that GZ250 making these noises or behaving this way.

Any further thoughts?

Doug

[Easy Rider]

Originally Posted by dougdftw

I checked more carefully and find that the shifting is always difficult.

The other issue is not one of clutch slippage but rather one of a bit of a clunk -

There is also bit of extra noise from the transmission. Sort of a constant chugging or grinding sound - even when sitting at idle in neutral.

Sounds pretty much like mine:

Shifting is stiff and noisy. Sometimes hard to get into 1st.
Shift needs to be "firm"; a little tension pre-load is best.
Not sure about your observed transmission noise but that is probably normal too. Thumpers have a different sound; might be the counter-balancer too.

Double check that clutch cable adjustment just for good measure.
I found that the tranny is a little smoother and quieter with Mobil 1 Synthetic bike oil; any appropriate full synthetic would probably help a bit.

Might want to have a look here:
Suzuki GZ250 Forum Suzuki GZ 250 Home Page on GZ250Bikes.Com Index

[dougdftw]

Thanks for the info and the link. lots of good comments over there too. I also noticed a reduction on transmission noise when I changed the to a better grade rated for use in motorcycles. I'll try the pure synthetic in the spring with a fresh filter. This sure is a fun 'round town little scooter. And just right for teaching a newbie.