How To Install a Clutch Kit on a 1982 Suzuki RM250 Dirt Bike

How To Install a Clutch Kit on a 1982 Suzuki RM250

Why replace the clutch on a 1982 RM250?

The 1982 Suzuki RM250 is a twostroke motocross machine with a wet, cableoperated multiplate clutch. Typical replacement triggers include slipping under hard acceleration, dragging that makes shifts difficult, inconsistent lever feel, or a lever that becomes unusually hard or soft. Aggressive starts, sand, heavy woods riding and old or incorrect oil accelerate wear. Installing a fresh clutch kit restores immediate power transfer, crisp throttle response and smooth shiftingexactly what you want when racing or riding tight tracks.

What's in the clutch system and what to inspect

Key components you'll see and should inspect during service:

• Clutch cover check for cracks, warped sealing surface and clean of debris
• Pressure plate surface condition and flatness
• Clutch springs check free length and evenness across springs
• Friction plates look for glazing, thinning, contamination or burned spots
• Steel drive plates discoloration from heat and any warping
• Clutch hub & clutch basket inspect splines and basket fingers for notching
• Inner hub splines ensure they aren't rounded or worn
• Thrust washer and pushrod confirm smooth movement and no heavy wear

Preparation

Park the RM250 on a solid stand so the bike is level and stable. Gather basic hand tools, a clutch kit sized for 1982 RM250, a new primary gear oil if you'll drain it, clean rags, and a tray for small parts. Because the RM250 uses a wet clutch, draining the crankcase isn't always required for clutch cover removal on every year, but be prepared to catch any oil and top off or change the oil afterward. Disconnect the clutch cable at the lever end to release tension before removing the cover.

Removing the clutch cover and parts

• Clean around the clutch cover to keep dirt out. Remove bolts in a crossing pattern to reduce stress on the cover.
• Carefully pull the cover free some oil will drip; have a drain pan ready.
• With the cover off, note the arrangement of springs, plates and any shims. Take photos for reference if helpful.
• Loosen and remove the clutch spring bolts evenly, removing springs and the pressure plate in sequence. Keep springs and bolts together so you can confirm correct reassembly order.
• Remove the friction and steel plates one by one. They should lift straight out; if any are stubborn, gently rock them free to avoid damaging the basket fingers.

Inspection checklist while disassembled

• Friction plates look for glazing (shiny smooth surface), burned spots, or heavy thinning. Replace any that show glazing or inconsistent thickness compared with others.
• Steel plates hold them up to light to see warping, and check for blue or dark discoloration from heat which indicates plate damage.
• Basket fingers run a fingernail along each ramp; feel for notching or sharp grooves. Notched fingers can cause dragging and inconsistent engagement and often require basket replacement.
• Hub splines ensure the splines are crisp and not rounded; excessive play here will cause chatter and uneven engagement.
• Springs compare free length sidebyside; any spring significantly shorter or softer should be replaced as a set to maintain even pressure.
• Pushrod & thrust washer confirm smooth travel and that the washer isn't disintegrated.
• Oil condition dark, burnt smelling oil suggests the clutch has overheated at times; plan to replace the oil and filter.

Preparing new clutch plates

Because the RM250 uses a wet clutch, soak the new friction plates in the correct engine oil for at least 15-30 minutes before assembly to ensure proper initial friction. Lay the plates flat in a clean container and pour oil so they're fully saturated. Steel plates don't need soaking but clean them of any factory coating or debris.

Reinstalling the clutch pack

• Install plates in the correct alternating orderfriction, steel, friction, steelending with the plate specified by the kit (typically a steel or friction plate depending on design). Use your photos as reference if you took any.
• Make sure each plate seats fully into the basket and hub grooves; rotate the hub as you fit plates to ensure alignment.
• Fit the pressure plate over the final plate and temperately compress the stack by hand.
• Install clutch springs and bolts, tightening them evenly in multiple stages so the pressure plate remains parallel. Do not overcompress one side before the other.

Reassembly and final adjustments

• Replace the clutch cover with a clean gasket or sealing surface. Tighten the cover bolts in a crisscross pattern until snug.
• If you drained oil, refill with the correct crankcase oil and check levels per normal running orientation.
• Reconnect the clutch cable. Adjust free play at the lever so there is a small amount of free movement enough to fully disengage the clutch when pulled but not so loose it causes late engagement. On the RM250, check for smooth cable operation and any binding through its routing; replace a rusty or frayed cable if present.
• If your clutch uses a cable, confirm the lever moves freely and the adjuster makes expected changes in engagement point. A worn cable can mimic a worn clutch, so inspect the outer and inner cable for fray or binding.

Breakin and ride check

After installation, warm the engine briefly and check for leaks around the cover. During the first few rides, avoid fullthrottle starts and long, slipping launchesgive the new plates time to bed in together. Expect the engagement point to settle after a short breakin. If shifting remains stiff or you notice chatter, recheck plate order, spring seating and basket notching.

Practical tips from the trail

• Motocross starts and aggressive clutch work wear these clutches fastestinspect earlier if you launch frequently.
• Riding in sand or mud accelerates slippage and contamination; change oil and inspect the clutch sooner if you ride those conditions a lot.
• Always replace springs as a set and use matched plates to avoid uneven pressure and premature wear.

Replacing the clutch on your 1982 Suzuki RM250 brings back predictable engagement, better throttle hookup and the confident shifting needed for motocross and aggressive trail riding. With basic tools and careful inspection, you can perform a reliable clutch service at home that keeps the RM250 responding like it should.

Related Shopping Categories

Shop Clutch Kits for a 1982 Suzuki RM250 Dirt Bike.

Shop Clutch Baskets for a 1982 Suzuki RM250 Dirt Bike.

Shop Clutch Springs for a 1982 Suzuki RM250 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 1982 Suzuki RM250 Dirt Bike.

Shop Clutch Covers for a 1982 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.