How To Install a Clutch Kit on a 1981 Suzuki RM80
Shop parts for a 1981 Suzuki RM80 Dirt Bike.Why replace the clutch on a 1981 Suzuki RM80?
The two-stroke, 80cc RM80 is a lightweight motocross/woods bike built for aggressive starts and frequent shifts. Over time the wet multi-plate clutch can show common symptoms that signal replacement is needed slipping under throttle, dragging that makes the bike creep in neutral, inconsistent lever feel, harder-than-normal shifting, or a lever that feels mushy or grabs suddenly. Proper clutch replacement restores engine-to-wheel power transfer, crisp throttle response, and reliable gear engagement, which is vital for MX launches and technical trail work.
Tools & materials to have on hand
- New clutch kit sized for 1981 Suzuki RM80 (friction plates, steel plates, springs if included)
- Clutch cover gasket or gasket maker
- Socket set, wrench set, screwdriver, pliers
- Torque wrench for final cover and bolt snugging (do not exceed common sense tightness)
- Drain pan, clean rags, parts tray
- Fresh engine oil suitable for air-cooled two-strokes
- Clutch cable lube or replacement cable if worn
- Brake cleaner or parts cleaner to degrease components
Prepare the bike
Work on a cool, level surface and secure the RM80 on a stand so the rear wheel clears the ground. Remove the seat and any plastics blocking the right-side clutch cover. On the 1981 RM80 you'll be dealing with a cable-operated wet multi-plate clutch, so before opening the case, back off the clutch lever free play and note the current cable adjustment. If you plan to replace engine oil, drain it into your pan before removing the clutch cover to minimize mess.
Remove the clutch cover & access the assembly
Clean the exterior of the clutch cover to prevent dirt falling into the engine. Loosen and remove the cover bolts in a crisscross pattern, then carefully remove the cover some oil will escape. Set the cover aside and remove the outer pressure plate by loosening the clutch spring bolts evenly a little at a time. Take care to keep springs and bolts together in the correct order.
Extract old plates & pressure components
With the pressure plate removed, pull out the friction plates and steel drive plates. On the RM80 the stack alternates friction then steel; keep the order as you remove them so you can confirm correct reassembly. Inspect each friction plate for glazing, uneven wear, or material thinning. Look at steel plates for blueing, discoloration or warping by placing them on a flat surface and rolling them gently to sense warps.
Inspect the basket, hub & related parts
Examine the clutch basket (outer) fingers for notching where the plates engage. Light notching is common but deep grooves will promote chattering and accelerated wear. Check the clutch hub splines and inner hub for burrs or wear. Inspect the thrust washer, pushrod, and bearing surfaces for scoring. If any components show excessive damage, replace them rather than only replacing plates.
Assess springs & cable system
Remove and compare clutch springs side-by-side. While you should not rely on specific lengths here, observe for uneven compression or obvious weakness. Replace springs if any are different or look fatigued. Because the RM80 uses a cable clutch, check the cable for freeness route it through the lever and clutch arm while feeling for binding. If the cable shows stretch, fraying, or sticky spots, replace it. Proper cable tension can mimic clutch wear if it's too tight or too loose.
Prepare new plates
When installing a wet clutch on this RM80, soak new friction plates in the correct two-stroke engine oil for at least 15-30 minutes before assembly. This helps prevent initial slippage and seating problems. Keep the steel plates clean and stack them as they will be installed.
Reassemble the clutch stack
Install plates in the original alternating order friction then steel and press them fully into the basket. Ensure each plate seats correctly in the basket grooves. Fit the pressure plate over the stack and install the clutch springs and bolts finger-tight in a cross pattern. Tighten springs evenly in stages until snug so the pressure plate is parallel to the stack. Re-check that the clutch pushes freely with the primary drive engaged by rotating the engine with the kickstarter very gently.
Final cover reinstallation & oil
Clean the cover mating surfaces and install a new gasket or apply gasket maker as preferred. Refit the clutch cover and start bolts by hand, then tighten in a crisscross pattern to an appropriate snugness. Refill the engine with fresh oil if drained earlier. Wipe any spills and ensure the fill level is correct per your usual routine for an air-cooled two-stroke.
Adjust clutch cable & test engagement
Set initial cable free play at the lever with a few millimeters of movement at the lever perch to allow full engagement without drag. On the RM80, small changes in cable tension significantly change engagement feel, so get the lever feel close and then fine-tune after a short break-in ride. Operate the lever repeatedly to confirm consistent, smooth movement and to seat the new plates. Check for any leaks at the cover gasket and that the engine turns over smoothly with the clutch pulled in.
Break-in and verification ride
Start with a gentle ride and a few low-load shifts to help the new plates mate properly to the basket and hub. Expect improved throttle response and tighter power transfer once the clutch seats. If you notice slipping after a short period, re-check cable adjustment and confirm springs are correctly torqued and installed evenly. If dragging persists, re-check stack order and pushrod clearance.
Why proper installation matters on an RM80
Because the RM80 is designed for quick, aggressive inputs on motocross tracks and trails, a correctly installed clutch provides immediate throttle connection and predictable shifting when you need it most. Proper inspection of the basket, hub splines, plates and springs avoids repeated service intervals and restores the bike's original behavior under load.
Related Shopping Categories
Shop Clutch Kits for a 1981 Suzuki RM80 Dirt Bike.
Shop Clutch Baskets for a 1981 Suzuki RM80 Dirt Bike.
Shop Clutch Springs for a 1981 Suzuki RM80 Dirt Bike.
Shop Inner Hubs and Pressure Plates for a 1981 Suzuki RM80 Dirt Bike.
Shop Clutch Covers for a 1981 Suzuki RM80 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.
