Star X/Gio 250cc Dirt Bike Clutch Issues.

baerboy22 · 03-17-2015, 11:38 AM

Hi, I'm really new to this forum, and the reason I am on here is because I cannot figure out how the clutch works on my dirt bike. I was hoping you one of you guys might have a understanding on how the clutches work on these bikes, as I can not find any information at all on Google/Youtube.

My bike is a Star X 250, which appears identical to the Gio X31 (Picture in the link). The problem I am having is; When I start the bike it neutral, it starts fine, then when I depress the clutch and put it into gear, it starts driving right away, before I even let out the clutch.
I already did everything it says to do in the other forums, checked the clutch cable, cleaned the clutch plates, etc.

Weldangrind · 03-17-2015, 03:48 PM

Welcome!

Your clutch operates just like a Honda XR200, and there are plenty of vids of that on Youtube.

Your cable needs some adjustment. How much freeplay do you have now? Freeplay is measured between the lever and the perch.

baerboy22 · 03-18-2015, 10:37 AM

Hey thanks, that helped a lot. I got it fixed last night, even took it for a quick test drive. Can't wait to hit the trails come sunday

Weldangrind · 03-18-2015, 10:49 AM

Glad to hear it!

May we see pics of your bike?

baerboy22 · 03-18-2015, 10:53 AM

I tried uploading some with my first post, but the file size it much too large due too my phone camera being too high res.
Did the link to the photo work in my original post?

Weldangrind · 03-18-2015, 10:55 AM

Nope. Just a little X.

Can you upload your pic to a third party, like Photobucket? If so, you could link it back here.

baerboy22 · 03-18-2015, 11:09 AM

http://i.imgur.com/Ntf1rWa.jpg This should work..

baerboy22 · 03-18-2015, 11:15 AM

I don't actually have a clutch cable on, in that picture.

Weldangrind · 03-19-2015, 12:46 AM

Sweet bike!

I linked the pic here, but it's too large. I'll try to reduce it.

Weldangrind · 03-19-2015, 01:00 AM

Name: Baerrboy Bike.jpg
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baerboy22 · 03-19-2015, 11:07 AM

I took it out for my first ride yesterday, was great. Had no issues

But I have 2 more questions for you, how much slack should the chain have (how loose/tight)? Also how tight should the rear axle bolt be? I recently took off my rear tire to fix a flat, now I can't figure out how tight the I should make the bolt. Do you have a bike similar to this? Could you take a close-up picture of your rear tire?

Mudflap · 03-19-2015, 01:18 PM

On just about any bike you determine the chain adjustment by lining up the centers of the countershaft, swing arm pivot bolt, and rear axle bolt, then adjust the chain for 10mm to 20mm movement.

Weldangrind · 03-23-2015, 11:05 AM

Agreed. That may require you to remove the shock the first time, but after that, you'll have a feel for proper chain tension.

I've never used a torque wrench on the axle nut, but I make sure they're tight. A little Loctite 242 is always a good idea.

baerboy22 · 04-14-2015, 11:42 AM

I have another question for you, since you seem to know quite a bit about these bikes, what air filter can I use in my bike? Mine is really beat up, but I don't know which one I can buy that would fit in it.

Weldangrind · 04-14-2015, 03:15 PM

Try this one: http://www.ebay.com/itm/Red-42mm-Ang...e5ec4c&vxp=mtr

It'll fit the carb, but I'm not sure if it will clear the frame properly. The good news is that the foam will just conform, and the price is certainly right. I've installed several of these filters, and I use Maxima Fab 1 filter spray on them. Use a light coat.

03-17-2015, 11:38 AM	#1
baerboy22 Join Date: Mar 2015 Location: Manitoba, Canada Posts: 7	Star X/Gio 250cc Dirt Bike Clutch Issues. Hi, I'm really new to this forum, and the reason I am on here is because I cannot figure out how the clutch works on my dirt bike. I was hoping you one of you guys might have a understanding on how the clutches work on these bikes, as I can not find any information at all on Google/Youtube. My bike is a Star X 250, which appears identical to the Gio X31 (Picture in the link). The problem I am having is; When I start the bike it neutral, it starts fine, then when I depress the clutch and put it into gear, it starts driving right away, before I even let out the clutch. I already did everything it says to do in the other forums, checked the clutch cable, cleaned the clutch plates, etc.
	0

03-17-2015, 03:48 PM	#2
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Welcome! Your clutch operates just like a Honda XR200, and there are plenty of vids of that on Youtube. Your cable needs some adjustment. How much freeplay do you have now? Freeplay is measured between the lever and the perch. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-18-2015, 10:49 AM	#4
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Glad to hear it! May we see pics of your bike? __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-18-2015, 10:55 AM	#6
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Nope. Just a little X. Can you upload your pic to a third party, like Photobucket? If so, you could link it back here. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-19-2015, 12:46 AM	#9
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Sweet bike! I linked the pic here, but it's too large. I'll try to reduce it. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-18-2015, 10:37 AM	#3
baerboy22 Join Date: Mar 2015 Location: Manitoba, Canada Posts: 7	Hey thanks, that helped a lot. I got it fixed last night, even took it for a quick test drive. Can't wait to hit the trails come sunday
	0

03-18-2015, 10:53 AM	#5
baerboy22 Join Date: Mar 2015 Location: Manitoba, Canada Posts: 7	I tried uploading some with my first post, but the file size it much too large due too my phone camera being too high res. Did the link to the photo work in my original post?
	0

03-18-2015, 11:09 AM	#7
baerboy22 Join Date: Mar 2015 Location: Manitoba, Canada Posts: 7	http://i.imgur.com/Ntf1rWa.jpg This should work..
	0

03-18-2015, 11:15 AM	#8
baerboy22 Join Date: Mar 2015 Location: Manitoba, Canada Posts: 7	I don't actually have a clutch cable on, in that picture.
	0

03-19-2015, 01:00 AM	#10
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	__________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

03-19-2015, 11:07 AM	#11
baerboy22 Join Date: Mar 2015 Location: Manitoba, Canada Posts: 7	I took it out for my first ride yesterday, was great. Had no issues But I have 2 more questions for you, how much slack should the chain have (how loose/tight)? Also how tight should the rear axle bolt be? I recently took off my rear tire to fix a flat, now I can't figure out how tight the I should make the bolt. Do you have a bike similar to this? Could you take a close-up picture of your rear tire?
	0

03-19-2015, 01:18 PM	#12
Mudflap Join Date: Sep 2014 Posts: 1,869	On just about any bike you determine the chain adjustment by lining up the centers of the countershaft, swing arm pivot bolt, and rear axle bolt, then adjust the chain for 10mm to 20mm movement.
	0

03-23-2015, 11:05 AM	#13
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Agreed. That may require you to remove the shock the first time, but after that, you'll have a feel for proper chain tension. I've never used a torque wrench on the axle nut, but I make sure they're tight. A little Loctite 242 is always a good idea. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

04-14-2015, 11:42 AM	#14
baerboy22 Join Date: Mar 2015 Location: Manitoba, Canada Posts: 7	I have another question for you, since you seem to know quite a bit about these bikes, what air filter can I use in my bike? Mine is really beat up, but I don't know which one I can buy that would fit in it.
	0

04-14-2015, 03:15 PM	#15
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	Try this one: http://www.ebay.com/itm/Red-42mm-Ang...e5ec4c&vxp=mtr It'll fit the carb, but I'm not sure if it will clear the frame properly. The good news is that the foam will just conform, and the price is certainly right. I've installed several of these filters, and I use Maxima Fab 1 filter spray on them. Use a light coat. __________________ Weldangrind "I figure I'm well-prepared for coping with a bike that comes from the factory with unresolved issues and that rewards the self-reliant owner." - Buccaneer
	0

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