How To Install a Clutch Kit on a 2006 Honda CRF250R Dirt Bike

How to Install a Clutch Kit on a 2006 Honda CRF250R

Why replace the clutch on your 2006 CRF250R

The 2006 Honda CRF250R is a 250cc motocross machine that sees hard launches, aggressive shifting and frequent heat cycles. Symptoms that usually point to a worn clutch include slipping under hard throttle, dragging or incomplete disengagement, inconsistent lever feel, hard shifts, or a mushy and variable engagement point. Because the CRF250R uses a wet, multiplate, cableoperated clutch, worn friction plates, glazed steels, weakened springs or notched basket fingers are the most common causes and a proper clutch kit installation restores throttle response, power transfer and crisp shifting.

Overview of the clutch components

• Clutch cover access point and seal surface.
• Pressure plate distributes spring force to the stack.
• Clutch springs provide clamping force; weak springs cause slipping.
• Friction plates absorb and transmit torque; inspect for glazing and wear.
• Steel drive plates transfer torque and resist heat; check for discoloration or warping.
• Clutch basket hub that holds the stack; finger notching leads to snagging and drag.
• Clutch hub & inner hub splines transmit torque from the gearbox; check for scalloping or rounded splines.
• Thrust washer & pushrod ensure smooth actuation and correct clearance.

Before you start prep and tools

Work on a clean, level bench or in the pit stand. You'll need basic hand tools, a torque wrench later for cover bolts if you use one, fresh engine oil & filter if you drain oil, a drain pan, a clean bucket for parts, rags and a small pick or punch to help with plate removal. The CRF250R is cableactuated inspect the clutch cable and lever before opening the clutch; poor cable routing, binding or excessive free play can mimic plate wear.

Step-by-step removal

1) Position the bike securely on a stand, warm the engine briefly then let it cool slightly to help oil flow. If the clutch cover drains oil on removal, place a drain pan under the bike and remove the drain plug or plan to catch oil when the cover comes off.

2) Remove shifter and any frame panels blocking access. Clean the clutch cover exterior to avoid contaminating the inside when opened.

3) Loosen and remove the clutch cover bolts in a crisscross pattern. Carefully pry the cover free there may be a small amount of oil. Remove the cover and set it aside on a clean surface.

4) With the clutch revealed, note the order of parts for reassembly. Loosen and remove the clutch spring bolts evenly in multiple passes to relieve pressure on the pressure plate. Remove the springs and pressure plate.

5) Pull out the plate stack alternating friction and steel plates and lay them out in order. Remove the pushrod and inspect the thrust washer and pushrod end for wear or scoring. Also rotate the clutch basket to inspect fingers for notching and the hub splines for wear.

Inspection checklist

• Friction plates look for glazing, burnt glaze, excessive thinning or missing friction material. Slight darkening is normal; deep glazing or grooves means replacement.
• Steel plates check for blueing, warpage or heavy scoring. Rub against a flat surface to feel for warpage if unsure.
• Springs compare free length to new springs; any noticeable sag, corrosion or cracked coils mean replace.
• Basket fingers look for deep grooves or notching where plates engage; severe notching can cause drag and should be addressed.
• Hub splines and thrust surfaces rounded splines or scored pushrod ends will cause poor engagement and should be replaced.
• Oil condition dirty, burnt oil accelerates clutch wear; if oil looks dark or metallic, change it when reassembling.

Preparing new plates & components

For a wet clutch like the CRF250R's, soak new friction plates in the correct engine oil for at least 15-30 minutes to allow the fibers to saturate. This reduces initial slipping and improves breakin. Keep steel plates and the basket/ hub clean and free of old grease or debris. Replace clutch springs and any other items in the kit.

Reinstallation

1) Reinstall the thrust washer and pushrod if removed. Slide the clutch hub and basket back into place, making sure splines align and the hub sits flush.

2) Stack plates in the correct sequence friction plate first or as the bike had originally (confirm by matching leftover stack orientation). Alternate friction and steel plates, pressing each fully into the basket seat. Ensure each plate engages the basket and hub properly some will locate on the hub splines, others on the basket fingers.

3) Fit the pressure plate over the stack and install the springs. Tighten spring bolts evenly in stages to seat the plate without cocking it. Do not overtighten during initial hand fitting; final torqueing can be done during final assembly if you choose to use a torque wrench.

4) Check free play at the lever. On the 2006 CRF250R's cable clutch, set the lever free play per the typical feel for this model small free play so the clutch fully engages at a consistent point. Inspect the cable for smooth travel; lubricate or replace a binding or frayed cable.

Reassemble cover & refill

Clean the clutch cover mating surfaces and replace the gasket or sealant as required. Reinstall the clutch cover and bolts, tightening evenly. If you drained oil, refill with the recommended type and quantity for your CRF250R; replace the oil filter if needed. Operate the lever several times to seat the plates, then start the bike and run through gears at low speed to confirm smooth engagement and no slipping.

Final checks and breakin

Ride gently for the first 20-30 minutes avoid aggressive launches to let the new plates bed in. Monitor lever feel and engagement point. If the clutch slips under load after breakin, recheck spring condition, cable tension and confirm plates were soaked and installed correctly. For persistent engagement issues, inspect the basket and hub again for subtle damage that can trap plates.

Performance context for the CRF250R

On a 250cc motocross bike like the 2006 CRF250R, clutch wear is often driven by repeated race starts, tight woods riding and heat from aggressive throttle work. Using proper oil intervals and avoiding excessive slipping during practice can extend clutch life. A correctly installed clutch kit returns quick throttle response, solid power transfer to the rear wheel and crisp shifts essential for competitive riding.

Related Shopping Categories

Shop Clutch Kits for a 2006 Honda CRF250R Dirt Bike.

Shop Clutch Baskets for a 2006 Honda CRF250R Dirt Bike.

Shop Clutch Springs for a 2006 Honda CRF250R Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2006 Honda CRF250R Dirt Bike.

Shop Clutch Covers for a 2006 Honda CRF250R 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.