Never Go Korean!

[beanietoast]

Hi All,
I'm new to this forum, so if I've posted in the wrong sub forum please do tell me.
Here's the problem(s).
I bought a Hyosung GT650S (2006/7 model (I think)) carbed; in Feburary 2015, I started riding it the beginning of March. Since then I've had nothing but problems with the bike.

When I bought it, the bike was idling very rough and was popping like mad, but from looking at forms, that's a common issue with the bike. After a while, the clutch started to slip and I found out I had a broken clutch plate. Replaced the clutch plate, then the second gear kept jumping and stuttering.

Which brings us to present day. The bike had been stuttering and jumping in second gear (only second) for about a week previously; and yesterday as I was riding along (not fast luckily!) the back wheel locked up and it would just rev and go no where. This was in first gear.

Here's the problem: The only way I could get it home was by putting it into neutral and riding while in neutral. When I go into first, the back tyre just locks up and it goes no where, the engine is still running at this point, but it feels as if it's a forced neutral, the engine just keeps revving without the bike going anywhere.

Is there any way I can diagnose clutch issues if there are any? I did inspect the clutch and all the plates seem okay, there's correct torque on the springs... One thing which I haven't tried was adjusting the clutch release rod. Would that do anything?

It may be wise to note I took it in for a servicing 3 days ago, and they tinkered with the gear lever and front sprocket (I think).
When I emptied to oil just now to see if there was any metal shards, there were slight metal sharding on the oil plug, but what interested me more is that there were thousands of little bubbles in the oil, and it was a yellow brown colour. The oil was apparently changed with the service.

The bike started within 1-2 seconds before this occured, now when I turn it on it takes about 5 seconds to actually start up, possibly longer.

A friend of mine said that the gear selector fork has been bent. I've found a SV650 MK1 engine for sale, I've checked the gear selector fork for both engines and the only difference is the 'shift fork groove width' is 0.5mm larger on the SV engine than the Hyosung, any advice on whether they could be interchangeable? The complete gearbox is intact in the SV engine, so that could be another possiblity.

TL;DR The bike rides away in neutral through fifth, but it's acting as if it's in first gear. Pulling away has no resistance even in fifth. First gear just locks up the back tyre when attempting to ride away and the engine just revvs when pulling the throttle. Found SV Engine, don't know if gearboxes are interchangeable

Thanks
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Hyosung GT650S 2006 (Carb)

[Rogerborg]

Oh, I wouldn't touch 'em after working on a GT125.

Here's some unhelpful vaguery: selector fork does sound like a plausible explanation, and I have a dim recollection of someone saying that the SV engine fits.

However, that person was a pathological liar [*] and it'd be an expensive and time consuming gamble to lose. The electrics are unlikely to be a straight plug-and-go job either.

This isn't what you want to hear, but I'd consider the value of the Hyosung as a pile of parts versus the cost of buying an actual SV or Bandit, Hornet, Fazer, or just about anything except a knock off with ropey parts supply.

Sorry, I'm really just sympathising. Dem feels. Hopefully you'll get a better answer from someone who's been inside one of these boxes.

[*]
https://rogerborg.dnsd.info/skywelder.jpg
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Biking is 1/20th as dangerous as horse riding.
GONE: HN125-8, LF-250B, GPz 305, GPZ 500S, Burgman 400 // RIDING: F650GS (800 twin), Royal Enfield Bullet Electra 500 AVL, Ninja 250R because racebike

[Taught2BCauti...]

[Llama-Farmer]

[beanietoast]

Ahaha thanks everyone for their replys. I think it might possibly be a gearbox issue, I just hope the SV650 MK1 engine gearbox will fit into the hyosung. IF not I'm screwed.

Also: Hi Harrison!
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Hyosung GT650S 2006 (Carb)