Honda vs. Gio Clutch

[Weldangrind]

I bought a replacement clutch on spec from Gio, and I decided to see if it was compatible with my son's '83 XR200R. I originally bought the clutch to have as a spare for our Beast.

The Gio clutch is quite substantial. The gear is wider and the basket holds seven friction discs instead of five on the Honda. As well, the Gio clutch uses six bolts to secure the assembly and uses lighter springs than the Honda unit. The Honda clutch uses four bolts with heavier springs. I'm theorizing that the Gio clutch is a clone of a later model Honda, and the changes to the bolts, springs and number of friction discs likely increase clamping force and reduce lever effort. All good things.

Here's the top view of the two assemblies that show the gear difference, along with the disc count:



Here's the top views that show the bolt difference:



Here's the Gio assembly installed on the Honda. It rubs on the oil filter rotor. :(



So, I installed five new friction discs and four new clutch plates from the Gio clutch in the Honda basket. Here's hoping that it feels like a brand new clutch.

[AZ200cc]

You have been busy, Damn shame that would not work after all that.

[SpudRider]

It's too bad the complete Gio clutch did not fit; however, I certainly hope the Gio clutch parts work well for you. Thank you for the great writeup, and the superb photos, WG.

Spud

[Weldangrind]

A good cup of coffee and some blues music allows me to work away in the shop for hours (when that rare opportunity presents itself). I'm still kind of wondering if the oil filter rotor from a later model would provide the clearance I need and allow the seven disc setup.

Hmmm...