How To Install a Clutch Kit on a 1981 Yamaha IT250 Dirt Bike

How To Install a Clutch Kit on a 1981 Yamaha IT250

Why replace the clutch on a 1981 Yamaha IT250

The 1981 Yamaha IT250 is a 250cc twostroke enduro/trail bike that uses a wet multiplate, cableactuated clutch. Over time the clutch can slip, drag, engage inconsistently, give a hard or spongy lever feel, or produce poor throttle response. Common riding patterns for this displacement and category aggressive woods work, frequent lowspeed technical shifting, sand, or repeated launch slips accelerate wear. Replacing the clutch kit restores direct power transfer, cleaner throttle response and crisp shift quality.

Tools, parts & prep

• New clutch kit sized for 1981 Yamaha IT250 (friction & steel plates, springs if included)
• Basic hand tools: socket set, screwdrivers, impact/ratchet, pliers
• Torque wrench for general engine fasteners (no model specs included)
• Fresh engine oil compatible with a wet clutch
• Drain pan, clean rags, a soft brush or toothbrush
• Clutch alignment check tool or feel manageable by hand

Preparing the bike

Park the IT250 on a stable stand or level surface and allow the engine to cool. Remove seat and side panels for access. If you prefer to avoid mixing oil, drain the engine oil into a pan the IT250's clutch operates in the crankcase oil, so removing oil reduces mess and simplifies cover removal. Clean the exterior of the clutch cover so dirt doesn't fall into the clutch during service.

Accessing and removing the clutch

• Disconnect the clutch cable at the lever to release tension. Note cable routing and any clamps.
• Remove the clutch cover bolts and lift the cover free. Some sealing compound or a gasket may be present; gently pry where necessary.
• With the cover off, you'll see the pressure plate secured by several springs and bolts. Loosen the clutch spring bolts evenly in a cross pattern to relieve spring pressure gradually this prevents distortion.
• Remove the pressure plate and clutch springs. Keep springs and bolts organized so you can reuse or compare them to new parts.
• Pull out the stack of friction and steel plates. On the IT250 expect alternating friction then steel plates; keep the removed stack in order for reference.

Inspection checklist what to look for

• Friction plates look for glazing, burnt or shiny surfaces, thinning material, or uneven wear. Deep grooves or missing friction material mean replacement.
• Steel drive plates check for blue discoloration from overheating or visible warping by laying on a flat surface and rocking gently.
• Clutch basket & hub inspect basket fingers for notching where plates engage. Notched fingers cause chattering and delayed engagement. Check inner hub splines for wear & mushrooming.
• Thrust washer & pushrod confirm the pushrod slides freely and the thrust washer isn't excessively worn or scored.
• Clutch springs compare free length and straightness to new springs; weak or uneven springs reduce clamp force and cause slip.
• Oil condition dark, burnt oil indicates overheating or contamination; replace oil before reassembly.

Deciding what to replace

If friction plates are glazed or worn and steel plates are discolored or warped, replace the full clutch kit (friction, steels and typically springs). Small groove wear on basket fingers can be acceptable, but deep notching should prompt basket replacement to prevent future problems.

Preparing new plates

As this is a wet clutch, soak new friction plates in fresh engine oil for at least 15-30 minutes prior to installation. This helps the plates seat quickly and prevents initial slippage. Lay steel plates out and inspect them one last time for burrs or coatings that could affect fit.

Reassembly proper sequence and technique

• Install the clutch pack in the same orientation you removed it. The IT250 uses alternating friction then steel plates; start and finish as the original stack did. A common setup is friction plate first against the hub but follow the sequence you noted.
• Ensure each plate fully seats into the basket and hub splines. Rotate the inner hub slightly as you add plates to help align splines.
• Reinstall the pressure plate over the stack. Fit clutch springs and tighten spring bolts evenly in a crisscross pattern until snug. Do not overtighten secure them progressively so the pressure plate sits flat.
• Spin the clutch assembly by hand to check for binding or abnormal resistance. The pack should compress and release smoothly as the pressure plate moves.
• Replace the clutch cover with a clean gasket or sealant as required. Tighten cover bolts progressively and evenly.

Final steps oil, cable adjustment & checks

Refill the engine with fresh oil of the correct type for twostroke wet clutch use. Reattach the clutch cable and set free play at the lever to a small, manufacturertypical amount just enough free play to release the clutch fully at idle. Check the cable for binding along its routing and lubricate the inner wire if needed so improper cable tension does not mimic clutch wear.

Breakin and test ride

After assembly, run the engine briefly at idle to circulate oil through the new plates. Take a short, controlled ride to bed the plates in avoid hard launches or sustained slipping for the first several miles. Pay attention to lever feel, engagement point consistency, and shift smoothness. If engagement is late or slipping persists, recheck plate order, spring condition and cable adjustment.

Maintenance notes specific to the IT250

The IT250's twostroke power delivery is abrupt compared with fourstrokes, so clutch condition strongly affects rideability. Regular oil changes and monitoring cable free play will extend clutch life. Heavy trail use, sand, or frequent clutch modulation will accelerate wear inspect plates periodically if you ride aggressively.

Wrap up

Replacing the clutch kit on your 1981 Yamaha IT250 brings back crisp throttle response and reliable power transfer. With organized work, careful inspection of the basket, hub and plates, and proper plate soaking and reassembly, a rider with basic to intermediate mechanical skill can complete the job and get the IT250 feeling tight and responsive again.

Related Shopping Categories

Shop Clutch Kits for a 1981 Yamaha IT250 Dirt Bike.

Shop Clutch Baskets for a 1981 Yamaha IT250 Dirt Bike.

Shop Clutch Springs for a 1981 Yamaha IT250 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 1981 Yamaha IT250 Dirt Bike.

Shop Clutch Covers for a 1981 Yamaha IT250 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.