How To Install a Clutch Kit on a 1982 Suzuki RM60 Dirt Bike

How to Install a Clutch Kit on a 1982 Suzuki RM60

Why Replace the Clutch on an RM60?

The 1982 Suzuki RM60 is a 60cc two-stroke youth motocross/trail bike with a wet, multi-plate, cable-operated clutch. Over time clutch slipping, dragging, inconsistent lever feel, hard shifting, or loss of drive are common reasons to replace the clutch pack. Aggressive starts, tight woods riding, sand, and high heat accelerate wear. Proper clutch replacement restores throttle response, improves power transfer, and returns crisp shift quality.

Tools & Preparation

• Basic hand tools - sockets, wrenches, ring or clutch nut tools compatible with the RM60
• Screwdrivers, needle-nose pliers
• Clean rags, degreaser, small brush
• Fresh engine oil appropriate for a wet clutch two-stroke (use the oil recommended for your engine)
• Drain pan and a safe bike stand
• New clutch kit (friction plates, steels, springs, pressure plate if included), replacement gaskets or O-rings if needed

Overview of Clutch Components

On the RM60 expect to see the clutch cover, pressure plate, multiple clutch springs, friction plates, steel drive plates, clutch hub and basket, inner hub splines, thrust washer and pushrod. Inspect each part as you disassemble the basket fingers, hub splines and plate surfaces are the usual wear points.

Step 1 Prepare the Bike

• Park the RM60 on a stable stand so the rear wheel can spin freely.
• Warm the engine briefly, then drain engine oil into a pan if your clutch cover is in the oil sump area many RM60s share oil with the clutch. Draining keeps the workspace cleaner and makes inspection easier.
• Clean the clutch cover area to prevent dirt entering the clutch during service.

Step 2 Remove the Clutch Cover and Accessorize

• Loosen and remove the clutch cover bolts and remove the cover. Pry gently where needed; use a soft mallet if stubborn.
• Note the clutch spring arrangement and any alignment dowels so reassembly is straightforward.

Step 3 Remove Springs, Pressure Plate & Plates

• Loosen clutch spring bolts evenly in a crisscross pattern to reduce distortion and remove springs and pressure plate.
• Slide out friction and steel plates one at a time. Keep the removed plates in order so you can compare with new parts and understand wear patterns.

Step 4 Inspect Basket, Hub & Splines

With plates out, inspect the clutch basket fingers for notching or grooves where the friction plates engage. Slide the inner hub and examine splines for burrs or uneven wear. Look for:

• Glazed or thinned friction plate material glazing appears shiny and hard, and reduces grip.
• Steel plates with blue discoloration or warping these indicate overheating and can cause chattering.
• Notched basket fingers severe notching can cause dragging or inconsistent engagement.
• Compressed or uneven springs springs should return their length and feel consistent when compared across the set.

Step 5 Decide What to Replace

Replace all friction plates and steels in a kit for consistent life and feel. Replace springs if they show collapse or inconsistent free length. If basket notching is minor, light filing and careful deburring can extend life; deep notches or damaged splines usually mean replacing the basket or hub for reliable clutch behavior.

Step 6 Soak New Friction Plates (Wet Clutch)

Soak new friction plates in fresh oil for at least 15-30 minutes so they are saturated. This reduces initial slipping and wear. Lay them flat in a shallow pan with enough oil to cover each plate.

Step 7 Reassemble Plates in Correct Order

• Install plates in the same pattern the bike came apart typically alternating friction plate, steel plate, across the clutch pack. Confirm the kit documentation or count the originals as you removed them.
• Ensure each plate seats fully against the basket and hub; slight twisting as you insert them helps alignment.

Step 8 Replace Pressure Plate & Springs Evenly

• Install the pressure plate and the clutch springs. Tighten springs gradually and evenly in a crisscross pattern so the pressure plate seats flat. Avoid over-tightening snug and even is the goal.
• Re-check that the pushrod and thrust washer are positioned correctly and move freely. Confirm there is no binding.

Step 9 Reinstall Clutch Cover & Refill Oil

• Replace the clutch cover with a new gasket or seal if necessary. Tighten cover bolts evenly.
• Refill engine oil to the proper level for the RM60. Proper oil condition is critical for wet-clutch life and consistent engagement.

Step 10 Adjust Cable Free Play & Test Engagement

Because the RM60 uses a cable-operated clutch, set free play at the lever to the recommended feel for this bike's cable actuation. Check the cable for kinks or binding along its run; smooth cable operation prevents slipping that mimics worn plates. With the engine off, pull the lever and rotate the rear wheel to confirm full disengagement. Start the engine and test engagement in low gear, using controlled throttle and clutch modulation.

Inspection Tips & Riding Context

In a 60cc motocross or trail application like the RM60, clutch wear often comes from repeated launch abuse, clutch slippage in sand, or overheating in long, technical rides. Using the correct oil and replacing the clutch as a full kit keeps performance consistent. After a rebuild, expect improved throttle connection, stronger low-end pull and smoother shifts particularly noticeable when exiting turns or during tight technical maneuvers.

Finish & Break-In

A short break-in period with moderate riding helps the new plates bed in. Avoid prolonged slipping or full-throttle launches for the first few rides. Re-inspect the cover for leaks and the clutch cable for correct adjustment after the initial ride.

Related Shopping Categories

Shop Clutch Kits for a 1982 Suzuki RM60 Dirt Bike.

Shop Clutch Baskets for a 1982 Suzuki RM60 Dirt Bike.

Shop Clutch Springs for a 1982 Suzuki RM60 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 1982 Suzuki RM60 Dirt Bike.

Shop Clutch Covers for a 1982 Suzuki RM60 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.