How To Install a Clutch Kit on a 1985 Yamaha XT350 Dirt Bike

How To Install a Clutch Kit on a 1985 Yamaha XT350

Why replace the clutch on a 1985 Yamaha XT350?

The 1985 Yamaha XT350 is a dualsport trail bike with a wet, multiplate, cableoperated clutch. Typical reasons to install a clutch kit include slipping under load, dragging or grabbing when releasing the lever, inconsistent lever feel, or hard shifting. Frequent trail use, sand, aggressive starts, or long climbs accelerate wear. A fresh clutch restores direct power transfer, crisper throttle response, and smoother shifts.

Prepare the bike

• Park the XT350 on a level surface and secure it with a stand so the left side is accessible.
• Clean around the clutch cover to keep debris out when you open the case.
• Because the XT350 uses a wet clutch, drain or remove oil only if your cover removal will allow fluid to escape. If you need to, drain into a clean pan; otherwise absorb oil with shop rags as you work.
• Gather tools: clutch tool or spring compressor, socket set, screwdriver, pliers, shop rags, fresh oil, new clutch kit, and a replacement gasket or sealant for the clutch cover.

Initial cable and lever checks

Before tearing into the clutch, inspect the cable. Check free play at the lever and run the cable through its full travel to detect sticking or binding. Cable stretch or kinking can mimic worn plates by preventing full disengagement. If cable operation is rough, replace or lubricate the cable first sometimes adjustment fixes the problem without a full clutch rebuild.

Removing the clutch cover and assembly

• Loosen and remove the clutch cover bolts evenly to avoid warping the cover. Keep fasteners organized.
• With the cover off, note the clutch spring layout and pressure plate orientation. Take a photo for reference if needed.
• Loosen clutch spring bolts in a crisscross pattern to relieve pressure evenly, then remove the pressure plate and springs.
• Remove the friction and steel drive plates one at a time, keeping their order. On the XT350 the stack alternates friction then steel, ending with a friction plate.

Inspect clutch components

Careful inspection tells you whether the basket or hub needs replacement along with plates:

• Friction plates look for glazing, heavy wear, or burned surfaces. Thin, hard, or shiny plates indicate replacement.
• Steel plates check for blueing, heat discoloration, or warping; slight surface marks are normal but severe warping will cause drag or chatter.
• Clutch basket examine finger grooves for notching where plate tangs ride. Significant notching can cause chattering and premature wear.
• Inner hub splines check for rounded or worn splines that let plates slip on engagement.
• Pressure plate and springs confirm springs are not broken, corroded, or weakened. Feel for reduced spring return if springs seem soft, replace them.
• Thrust washer and pushrod inspect for burrs, scoring, or excessive play that can affect engagement.

Preparing new plates

Because the XT350 uses a wet clutch, soak new friction plates in clean engine oil for at least 15-30 minutes before installation so they're fully saturated. This reduces initial slipping and helps even wear. Use the engine oil grade you normally run in the bike.

Reassembling the clutch stack

• Install the clutch plates in the correct alternating order friction, steel, friction keeping the orientation consistent with how you removed them.
• Make sure each plate seats fully and the tangs engage the basket properly. Check that plates slide smoothly on the hub splines.
• Reinstall the pressure plate, aligning any locating pins or tabs as they were removed.
• Fit clutch springs and tighten their bolts evenly in a crisscross pattern to compress the pack uniformly.
• If your kit includes a new thrust washer or pushrod parts, install them now and ensure the pushrod moves freely without binding.

Clutch cover and oil

Fit a new clutch cover gasket or apply a thin, even bead of sealant per your usual practice. Reinstall the cover bolts handtight to align, then snug them progressively. If you drained oil earlier, refill with the correct volume and grade of engine oil for the XT350. Proper oil condition is critical dirty or incorrect oil accelerates clutch wear and can change feel.

Cable adjustment and final checks

• Adjust clutch cable free play at the lever so there's a small amount of slack at rest enough for full engagement but not so loose that plates drag. Small increments matter; recheck after a short test ride and retorque cover bolts if needed.
• With the engine off, pull the clutch lever several times to seat the plates and check engagement point.
• Start the bike and test clutch operation in first gear in a safe area. Make short runs to confirm no slipping, grabbing, or chatter and that shifts are crisp.

What to watch for after installation

On the first rides expect a short beddingin period. If you still notice slipping, check for a sticking cable, compromised springs, or damaged basket/hub components. Hard shifts or chatter usually point to basket notching, warped steel plates, or incorrect plate order. Properly installed, a new clutch kit returns your 1985 Yamaha XT350's throttle response and shift quality to expected dualsport performance.

Related Shopping Categories

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Shop Inner Hubs and Pressure Plates for a 1985 YAMAHA XT350 Dirt Bike.

Shop Clutch Covers for a 1985 YAMAHA XT350 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.