How to Install a Clutch Kit on a 1985 Suzuki RM250

Shop parts for a 1985 Suzuki RM250 Dirt Bike.

Replacing the clutch on a 1985 Suzuki RM250 restores crisp engagement, full power transfer and predictable shiftingespecially important on a twostroke motocross machine that sees aggressive launches and high RPM work. The RM250 uses a wet, multiplate cableoperated clutch. Below is a practical, stepbystep guide for a rider with basic to intermediate mechanical skills.

Why replace the clutch?

  • Slipping during hard acceleration or when climbing engine revs rise without matching ground speed.
  • Dragging or incomplete disengagement difficulty shifting or the bike creeping in gear.
  • Inconsistent lever feel spongy or excessively tight cable operation can mimic internal wear.
  • Hard shifting, burnt smell, or poor throttle response signs plates or springs are compromised.

Tools, supplies & prep

  • Basic hand tools: sockets, wrenches, screwdrivers, pliers
  • Clutch kit sized for 1985 Suzuki RM250 (friction plates, steels, springs, thrust washer if included)
  • Fresh gear oil compatible with twostroke wet clutch use
  • Drain pan, clean rags, small container for fasteners, solvent for cleaning parts
  • Workstand or secure place to keep the bike upright

Prepare the bike

  • Position the RM250 on a stable stand with the engine cool and in neutral.
  • Remove any plastics or components blocking access to the clutch cover.
  • If your RM250's clutch cover is in contact with oil, drain the transmission/oil if required for your bike's layout so you don't spill when the cover comes off.
  • Clean the exterior of the clutch cover so debris doesn't fall inside once opened.

Remove the clutch cover and assembly

  • Loosen and remove the clutch cover bolts in a cross pattern to reduce stress. Keep bolt locations organized.
  • Pull the cover freeexpect some oil residue. Inspect the inside of the cover for metal particles or excessive wear signs.
  • Loosen the clutch cable at the lever or adjuster to reduce tension on the pushrod.
  • Remove the clutch spring bolts evenly in stagesdo not remove one spring fully before the others. This avoids warping the pressure plate.
  • Take off the pressure plate and set it aside, then remove friction plates and steel drive plates one at a time, noting their orientation and order.

Inspect clutch components what to look for

  • Friction plates: check for glazing, thinness, or oilsoaked surface that no longer bites. Glazed plates will look shiny and feel smooth.
  • Steel plates: look for blueing (sign of overheating), warping, rough edges or heavy scoring.
  • Basket and hub: inspect basket fingers and hub splines for notching or hooked wear where plates engage. Notched fingers cause chatter and poor release.
  • Springs: compare free length to new springs; fatigued springs compress more easily and reduce clamp force.
  • Inner hub splines and thrust washer/pushrod: ensure splines are not rounded and the pushrod moves freely without binding.
  • Clutch cover: examine the mating surface and oil passages for debris.

Deciding what to replace

On a 1985 Suzuki RM250, replace any glazed friction plates and badly discolored or warped steel plates. Replace springs if they show visible fatigue. If the basket fingers or hub splines are noticeably notched, replace or service those componentsminor notching can sometimes be smoothed, but deeper wear needs replacement to prevent rapid recurrence of problems.

Soak and prepare new parts

  • Soak new friction plates in fresh gear oil for at least 15-30 minutes before installation. This helps initial clutch engagement and reduces early wear.
  • Wipe new steel plates clean; inspect for flatness and finish.

Reinstalling the clutch pack

  • Install plates in the original ordertypically alternating friction plate then steel plate. Begin with the part that first mates to the inner hub depending on how your RM250's pack is arranged.
  • Ensure friction plates seat fully into the basket fingers and hub splines align properly. If a plate binds on a spline, rotate slightly until it drops in smoothly.
  • Reposition the pressure plate over the pack, keeping it parallel to the hub.
  • Install clutch springs and tighten spring bolts evenly in multiple passes to seat the assembly. Tighten incrementally so the pressure plate stays squaredo not torque to any quoted factory values here.
  • Check pushrod and thrust washer placement as you reassemble to ensure proper transfer of lever force to the pack.

Clutch cable specifics for the RM250

The 1985 Suzuki RM250 uses a cableoperated clutch, so correct cable routing and free play are essential. Before finalizing the cover:

  • Adjust cable free play at the lever so there is a small amount of free movement at the lever pivot before the clutch begins to pullthis avoids constant partial engagement that wears plates prematurely.
  • Inspect the cable for fraying, kinks or binding. Replace the cable if you find stiff or uneven movement.
  • Lubricate the cable where appropriate to keep operation smooth; a binding cable can mimic a failing clutch pack.

Final assembly and checks

  • Clean mating surfaces and reinstall the clutch cover, aligning any dowels or locating tabs.
  • Refill with the correct oil for a twostroke wet clutch setup and check levels after a short run; change oil if contaminated with metal debris.
  • With the engine off, confirm clutch lever travel and engagement the lever should disengage fully and return smoothly.
  • Start the RM250 and test clutch engagement in first gear at low speed in a controlled area. Listen and feel for smooth engagement, no dragging and no chatter.

Ride context how use affects wear

On a 250cc motocross twostroke like the 1985 RM250, clutch wear accelerates with aggressive starts, frequent slipping in sand or tight woods and running with incorrect oil. Keeping the clutch properly adjusted and replacing worn parts restores throttle response and crisp power delivery that you need for race launches and technical sections.

Maintenance tips to extend clutch life

  • Keep the cable lubricated and free play correctly set.
  • Use the recommended oil type and change it at regular intervals to prevent clutch contamination.
  • Inspect clutch components periodically if you ride in heavy sand or mudcontaminants increase wear.

Follow these steps and your 1985 Suzuki RM250's clutch will come back to lifereturning the reliable engagement and predictable power transfer a dirt rider depends on.

Related Shopping Categories

Shop Clutch Kits for a 1985 Suzuki RM250 Dirt Bike.

Shop Clutch Baskets for a 1985 Suzuki RM250 Dirt Bike.

Shop Clutch Springs for a 1985 Suzuki RM250 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 1985 Suzuki RM250 Dirt Bike.

Shop Clutch Covers for a 1985 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.