How to Install a Clutch Kit on a 1981 Suzuki RM250
Shop parts for a 1981 Suzuki RM250 Dirt Bike.Why replace the clutch on a 1981 Suzuki RM250?
The 1981 Suzuki RM250 is a two-stroke motocross bike with a wet, multiplate, cableoperated clutch. Over time the clutch can show symptoms such as slipping under throttle, dragging at idle, inconsistent lever feel, hard or missed shifts, and a vague engagement point. Aggressive starts, sand, woods riding, overheated oil, or long race seasons accelerate wear. Replacing worn friction plates and renewables restores crisp throttle response, full power transfer, and predictable shifting.
Tools & supplies to gather
- Basic hand tools: metric sockets, ratchet, Allen keys, screwdrivers
- Clutch kit sized for a 1981 Suzuki RM250 (friction plates, steels, springs, thrust washer if included)
- New clutch cable (optional) and fresh engine oil suitable for twostroke wet clutches
- Clean rags, small container for old parts, drain pan
- Soft mallet and a clean workbench or sturdy bike stand
Preparing the bike
Park the RM250 upright on a stand with the transmission in neutral. Work on a clean surface to avoid introducing grit into the clutch. Because the RM250 uses a wet clutch bathed in engine oil, you may choose to drain the oil prior to opening the clutch cover to limit spillage; otherwise have rags and a pan ready. Disconnect the negative battery lead if fitted, and loosen the clutch cable at the lever to relieve tension.
Removing the clutch cover and assembly
Clean the area around the clutch cover to prevent debris falling inside. Remove the cover bolts and pull the cover offnote seals and gasket condition as you go. With the cover removed you'll see the pressure plate secured by multiple clutch springs. Loosen springs evenly in a crisscross pattern to relieve pressure slowly and prevent warping the pressure plate. Remove the springs and the pressure plate, then slide out the stack of friction and steel drive plates.
Inspection & diagnosis specific to the RM250
- Friction plates check for glazing, thinning, cracked rivets, or burned surfaces. Glazed plates often feel smooth and shiny rather than coarse.
- Steel drive plates hold each plate up to a light and look for blueing or warping. Warped steels will not sit flat and cause grabbing or chatter.
- Clutch basket & hub rotate the basket and inspect the finger tips for notching or grooves where the plates engage. On a 1981 RM250 this can cause uneven release and chatter under load.
- Inner hub splines ensure splines aren't excessively rounded or chewed; minor wear is normal but severe wear affects lockup.
- Springs & pressure plate check spring free length and evenness. If springs sit shorter or vary significantly, replacement is necessary.
- Thrust washer & pushrod confirm smooth movement and no galling. Replace if scored or damaged.
Clutch cable & actuation check
Because the RM250 uses a cable clutch, inspect the cable for fraying, kinks, and binding in the lever or actuator box. Measure and set free play at the lever so there's a small amount of slack; excessive free play or tightness can mimic worn plates. If the cable feels rough or binding during operation, replace it while the clutch is disassembled to save time.
Preparing new plates
New friction plates for this wet clutch should be soaked in the recommended twostroke oil for at least 15-30 minutes to allow full saturation. This reduces initial slipping and wear. Keep the new steel plates clean and flat; if a kit includes a new thrust washer or pushrod components, have them on hand for reassembly.
Reassembly plate order & fit
Rebuild the clutch stack in the same order it came outtypically alternating friction plate, steel plate, friction, steel, and so on, ending with the pressure plate. Ensure each plate fully engages the basket fingers and hub splines. If the RM250's clutch kit calls for a specific orientation for any plate, follow the kit's guidance; otherwise mirror the original pattern. Compress the stack gently while aligning the pressure plate.
Installing springs & closing up
Install new or inspected clutch springs, tightening the spring bolts evenly in a crisscross pattern to seat the pressure plate flat. Tighten by hand until snug; avoid overtightening. Refit the clutch cover with a clean gasket or fresh sealant as appropriate, keeping oil pathways clear. Reinstall the cable and set initial lever free playtypically a small amount of slack at the lever tip so the first few millimeters of movement take up the free play before engagement.
Refill oil & final checks
Refill the engine with fresh twostroke oil at the correct level for a wet clutch system. With the engine off, operate the clutch lever several times to confirm positive engagement and smooth movement. Start the RM250 and test clutch engagement in first gearif the bike creeps or slips excessively, recheck plate order, spring seating, and cable adjustment. Listen for unusual noises and feel for consistent lever pull across its travel.
Riding context & maintaining clutch life
The RM250's 250cc motocross powerplant rewards precise clutch workaggressive starts, constant slipping in tight woods, or sand can wear plates quickly. Use a proper twostroke oil mix and change oil regularly to avoid clutch glazing from contaminated or overheated oil. Adjust cable free play periodically and avoid riding with the clutch partially held open for prolonged stretches.
Final notes
Replacing the clutch kit on your 1981 Suzuki RM250 returns crisp power delivery, better throttle connection, and predictable shiftingessential for competitive or hard trail riding. Take your time inspecting the basket, hub, springs, and plates; replacing the cable while you have the clutch apart often prevents early return visits. With correct plate soaking, careful reassembly, and proper cable adjustment your RM250 will be back to strong, consistent engagement.
Related Shopping Categories
Shop Clutch Kits for a 1981 Suzuki RM250 Dirt Bike.
Shop Clutch Baskets for a 1981 Suzuki RM250 Dirt Bike.
Shop Clutch Springs for a 1981 Suzuki RM250 Dirt Bike.
Shop Inner Hubs and Pressure Plates for a 1981 Suzuki RM250 Dirt Bike.
Shop Clutch Covers for a 1981 Suzuki RM250 Dirt Bike.
Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.
