125cc Gio dirt bike clutch problems

heretic · 08-18-2009, 11:34 PM

My daughter heated up her 125 today so hot it melted the end of the oil dipstick off 8O Now the clutch will not work changed the oil .tried adjusting it still the clutch will not disengage .Any ideas?I took the case of but all seems fine there .Anybody know how to get the clutch off is there a special tool for undoing the nut underneatth the plate .Please help shes devesttaed thinking she might not ride again this year .The bike only has about 20 hrs on it :(

Reveeen · 08-19-2009, 08:09 AM

so hot it melted the end of the oil dipstick off

These things seem to run hot, but not quite that hot, what are you running for oil? Have you adjusted the valves? (a "tight" valve will cause it to run hot).

Valve adjustment info:
http://www.hooperimports.com/showpages.asp?pid=1016

Break-in procedure:
http://www.hooperimports.com/showpages.asp?pid=1026

Ok, now clutch adjustment:
The cable has 2 adjustment spots and under the small right side cover there is a coarse adjustment.

Taking the clutch apart:
General info:
http://www.dansmc.com/clutches.htm
Specifically (the tool required)
http://www.chinariders.net/modules.p...ewtopic&t=8178

Weldangrind · 08-19-2009, 11:25 AM

This is cheap insurance to prevent another overheated clutch: http://www.scooterparts4less.com/web..._OilCooler.htm

And here are the tools: http://www.scooterparts4less.com/web...lutch_Tool.htm

heretic · 08-19-2009, 11:15 PM

Thanks guys thats all the info i needed . 8) I'm thinking maybe the plates are stuck together from the plastic .Im going to take it apart and try repairing it before ordering another clutch .You guys are awesome thanks again that oil cooler looks like a must have .Thanks again

AZ200cc · 08-20-2009, 12:32 AM

Good luck, Hope that's all that melted 8O Did it sit idle while running for a long time? Or did the motor get caked with mud?

Weldangrind · 08-20-2009, 01:50 AM

If you move forward with the oil cooler, might I recommend a muffin fan? Muffin fans (the same type found in PC cases) run on 12 volts, and it could be easily zip-tied to the oil cooler. I'm sure that you could find a 12 volt power source coming off of the stator.

If not, there's always LynnEdwards!

08-18-2009, 11:34 PM	#1
heretic Join Date: Aug 2009 Posts: 2	125cc Gio dirt bike clutch problems My daughter heated up her 125 today so hot it melted the end of the oil dipstick off 8O Now the clutch will not work changed the oil .tried adjusting it still the clutch will not disengage .Any ideas?I took the case of but all seems fine there .Anybody know how to get the clutch off is there a special tool for undoing the nut underneatth the plate .Please help shes devesttaed thinking she might not ride again this year .The bike only has about 20 hrs on it :(
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08-19-2009, 11:25 AM	#3
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	This is cheap insurance to prevent another overheated clutch: http://www.scooterparts4less.com/web..._OilCooler.htm And here are the tools: http://www.scooterparts4less.com/web...lutch_Tool.htm __________________ 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
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08-20-2009, 12:32 AM	#5
AZ200cc Join Date: Apr 2007 Location: Show Low Arizona Posts: 2,889	Good luck, Hope that's all that melted 8O Did it sit idle while running for a long time? Or did the motor get caked with mud? __________________ <br />2001 Suzuki DR200SE<br />1997 Suzuki RM250 YIKES<br />1995 Yamaha Breeze 125 daughters<br />1991 Honda XR80r Restored<br />maybe a 2003 Yamaha TTR90
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08-20-2009, 01:50 AM	#6
Weldangrind Join Date: Mar 2009 Location: Sardis, BC, Canada Posts: 25,977	If you move forward with the oil cooler, might I recommend a muffin fan? Muffin fans (the same type found in PC cases) run on 12 volts, and it could be easily zip-tied to the oil cooler. I'm sure that you could find a 12 volt power source coming off of the stator. If not, there's always LynnEdwards! __________________ 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
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08-19-2009, 08:09 AM	#2
Reveeen Join Date: Jun 2009 Location: orbital platform Posts: 741	so hot it melted the end of the oil dipstick off These things seem to run hot, but not quite that hot, what are you running for oil? Have you adjusted the valves? (a "tight" valve will cause it to run hot). Valve adjustment info: http://www.hooperimports.com/showpages.asp?pid=1016 Break-in procedure: http://www.hooperimports.com/showpages.asp?pid=1026 Ok, now clutch adjustment: The cable has 2 adjustment spots and under the small right side cover there is a coarse adjustment. Taking the clutch apart: General info: http://www.dansmc.com/clutches.htm Specifically (the tool required) http://www.chinariders.net/modules.p...ewtopic&t=8178
	0

08-19-2009, 11:15 PM	#4
heretic Join Date: Aug 2009 Posts: 2	Thanks guys thats all the info i needed . 8) I'm thinking maybe the plates are stuck together from the plastic .Im going to take it apart and try repairing it before ordering another clutch .You guys are awesome thanks again that oil cooler looks like a must have .Thanks again
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