How To Install a Clutch Kit on a 1982 Yamaha IT250 Dirt Bike

How To Install a Clutch Kit on a 1982 Yamaha IT250

Why replace the clutch on your 1982 Yamaha IT250

The 1982 Yamaha IT250 is a two-stroke trail/enduro machine built for technical riding. Over time the wet multi-plate clutch can show signs of wear slipping under load, dragging at idle, inconsistent lever feel, hard or missed shifts all symptoms that reduce throttle response and power transfer. Replacing the clutch kit restores crisp engagement, reliable launches, and consistent shifting so the bike performs in tight woods, sand, or aggressive trail riding.

System overview specific to the 1982 IT250

This generation uses a cable-operated, wet multi-plate clutch. That means you'll deal with a clutch cable and lever free play, plus a stack of alternating friction and steel plates inside a clutch basket and hub. Cable stretch or binding can mimic plate wear, so check the cable and lever feel as part of diagnosis.

Tools & supplies to have ready

• Basic socket and wrench set
• Screwdrivers and pliers
• Clutch holding tool or suitable alternative
• Replacement clutch kit (friction plates, steels, springs as applicable)
• Fresh engine oil of correct type for wet clutches
• Clean rags, drain pan, and parts tray
• Small pick or magnet for thrust washer & pushrod inspection
• Grease for pushrod/contact surfaces

Preparing the bike

Park the IT250 on a level surface and secure it on a stand. Warm the engine briefly then shut off warm oil drains more completely. Remove the right-side footpeg or any seizing guards that block the clutch cover. If you rotate the bike frequently in your shop, lay down clean rags to catch oil and keep nicks off the frame.

Drain oil & remove the clutch cover

Because the clutch runs wet, drain the engine oil into a pan first to avoid spills when the cover comes off. After draining, remove the clutch cover bolts and slowly pry the cover free some residual oil will remain. Keep the gasket and small parts organized. Note the orientation of the cover and any shims or washers you encounter.

Inspect and remove the clutch pack

• Loosen the clutch springs evenly in a star pattern to relieve pressure on the pressure plate. Remove springs and pressure plate.
• Slide out the friction and steel plates. Take photos or count the sequence as you remove them — most kits alternate friction then steel, finishing with a friction plate.
• Inspect each friction plate for glazing, uneven wear, or burned discoloration. Light glazing can sometimes be deglazed, but deep wear requires replacement.
• Check steel plates for blueing or warping by sight and feel; replace if warped or heavily discolored.

Inspect basket, hub & internal components

Examine the clutch basket fingers for notching where the plates engage. Notched fingers cause drag and chatter; light notches can be smoothed with a file, but deep notching means replacement. Check the inner hub splines for wear and free movement of plates. Inspect the thrust washer and pushrod for scoring or flat spots and confirm the pushrod moves freely. Look over the pressure plate face for hot spots.

Clutch cable & lever checks

Before reassembly verify cable free play at the clutch lever slight free play is normal and prevents drag. Check the cable for stretch, frayed strands, or binding through the lever perch and adjust the cable at the lever or adjuster near the clutch arm. A worn or sticky cable can make a new clutch feel poor, so replace or lubricate the cable if necessary.

Soaking new friction plates & preparing the kit

For a wet clutch like the IT250's, soak new friction plates in fresh engine oil for at least 15-30 minutes to let fibers saturate. This reduces early slippage and helps break-in. Keep steel plates dry during this step, then dip them briefly in oil before assembly.

Reinstalling plates and springs

• Install the clutch pack in the same order you removed it — usually friction, steel, friction, steel, ending with a friction plate. Ensure each plate seats fully into the basket and hub.
• Fit the pressure plate over the pack. If the kit includes new springs, use them; otherwise inspect old springs for full free length and replace any that look weak or compressed.
• Install springs and start the spring bolts by hand. Tighten them progressively in a star pattern to compress the plate evenly.

Reassembling the cover & refilling oil

Clean mating surfaces and replace the gasket if needed. Reinstall the clutch cover and snug bolts evenly. Refill the engine with the correct oil for a wet clutch application, then run the bike briefly and recheck oil level when warm to ensure correct fill.

Final clutch adjustment and break-in

Set lever free play to a small amount and confirm smooth engagement through the entire lever travel. With a cable-operated clutch you may need to fine-adjust the cable at the lever or adjuster under the left crankcase. After installation, avoid aggressive launches for the first few tanks of oil; allow the new plates to bed in by riding with moderate clutch use. Expect engagement to firm up and shifting to smooth out with a short break-in.

Troubleshooting tips and riding context

• If slipping returns quickly, recheck plate soak, spring condition, and cable adjustment.
• Drag or hard engagement often points to cable binding, a misassembled plate order, or a warped plate.
• Avoid high heat riding without fresh oil sandy, tight-woods, and aggressive motocross starts stress the clutch more on a 250cc two-stroke like the IT250.

What proper installation restores

On the 1982 Yamaha IT250 proper clutch replacement and adjustment restores direct throttle response, reliable power transfer to the rear wheel, crisp shifts, and consistent lever feel. That translates to better control on technical trails, cleaner holeshots in tight conditions, and more confidence in demanding terrain.

Related Shopping Categories

Shop Clutch Kits for a 1982 Yamaha IT250 Dirt Bike.

Shop Clutch Baskets for a 1982 Yamaha IT250 Dirt Bike.

Shop Clutch Springs for a 1982 Yamaha IT250 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 1982 Yamaha IT250 Dirt Bike.

Shop Clutch Covers for a 1982 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.