How To Install a Clutch Kit on a 2009 Husqvarna TE310 Dirt Bike

How to Install a Clutch Kit on a 2009 Husqvarna TE310

Why replace the clutch on a 2009 Husqvarna TE310

The 2009 Husqvarna TE310 is a 310cc enduro machine that sees a lot of low-speed, technical load on the clutch tight woods, sand bogs, and aggressive hill work accelerate wear. Signs you need a clutch kit include slipping under load, dragging in neutral or low gears, inconsistent lever feel, hard shifting, or a lever that progressively needs more travel. Replacing the wet multiplate clutch restores direct throttle response, solid power transfer, and predictable shift quality.

Clutch system characteristics on the 2009 TE310

The TE310 of this era uses a cableoperated, wet multiplate clutch. That means plates run in engine oil and engagement is controlled by a cable out of the lever. Because the cable can stretch or bind, a poor lever feel can mimic worn plates check cable condition and free play before tearing the clutch apart.

Tools & materials

• New clutch kit (friction plates, steel drive plates, springs, thrust washer if included)
• Proper engine oil for the TE310 (recommended type on bottle) and an oil drain pan
• Basic metric hand tools, torque wrench for case bolts, clutch holding tool or method
• Feeler gauges, clean rags, parts tray, and a small brush
• Rubber gloves and fresh gasket or silicone if clutch cover gasket is onetime use

Preparation

Work on a level surface with the bike secured upright. Warm the engine briefly to thin the oil, then drain the oil into a pan if the clutch cover sits below the oil level (common on the TE310). Clean the cover area so dirt doesn't fall into the clutch. If you don't need to drain oil because the cover is above the oil level, still wipe around the cover and remove any debris.

Removing the clutch cover and components

• Loosen the clutch cable at the lever and push the cable out of the clutch arm to release tension.
• Remove the clutch cover bolts in a star pattern to avoid warping. Pry the cover free carefully tap gently if it's stuck, don't gouge the mating surfaces.
• With the cover off, remove the retaining bolts for the pressure plate evenly, loosening them a little at a time to release spring tension safely.
• Lift off the pressure plate and remove the clutch springs. Keep spring positions and orientation noted; many kits reuse the same pattern.
• Slide out the friction plates and steel drive plates, keeping them in order as you remove them so you can confirm correct alternating placement during reassembly.

Inspection what to look for

• Friction plates check for glazing, thinning, burned surfaces or excessive wear. A glazed plate will be shiny and hard instead of textured.
• Steel drive plates inspect for blue discoloration or warping. Warped plates can cause drag and noise.
• Clutch basket and hub inspect basket fingers for notching or grooves where the plates contact. Notching causes chattering and accelerated wear; mild notches can be smoothed with crocus cloth, deep notches require replacement.
• Inner hub splines look for burrs or wear that allow play between hub and primary shaft.
• Thrust washer and pushrod check for scoring or excessive wear. Replace if there's visible damage.
• Springs compare the free length and look for uneven compression or rust. Replace springs if they look weak or uneven.
• Oil note the condition of the drained oil. Burned or contaminated oil accelerates clutch wear; fresh oil is vital on reassembly.

Preparing new plates

If you're installing a new wet clutch kit, soak the friction plates in clean engine oil for at least 15-30 minutes so they absorb oil and prevent initial slippage. Steel plates do not need soaking but should be wiped clean of any packing oil before assembly.

Reassembly plates, springs, and pressure plate

• Install plates in the correct alternating order friction, steel, friction until the stack is complete. Ensure each plate seats fully in the basket fingers and onto the hub splines.
• Fit the pressure plate over the stack. If the kit includes a thrust washer or special spacer, install it where it was originally located.
• Install clutch springs and handstart the retaining bolts. Tighten bolts gradually in a crisscross pattern so the pressure plate seats evenly.
• Confirm the clutch lever has typical free play at the lever perch; if installing new springs or thicker plates, you may need to adjust cable free play to manufacturerrecommended feel (feel that allows full disengagement without excessive slack).

Clutch cable check & adjustment

Since the 2009 TE310 uses a cable clutch, inspect the cable for fraying, kinks, or binding through the lever and clamps. Adjust free play at the lever so there's a small amount of finger travel before engagement too tight can cause dragging, too loose causes slippage. Lubricate the cable if it feels stiff.

Final steps cover, oil, and test

• Clean the clutch cover mating surface and replace the gasket if required. Reinstall the cover carefully and tighten bolts in a cross pattern.
• Refill the engine with fresh oil to the correct level for your TE310. Use the oil type appropriate for a wet clutch application.
• Before first ride with the engine off operate the clutch lever several times to circulate oil through the plates and check lever feel. Start the bike and test in low gear, pulling in the clutch through a few engagements to bed the plates into each other gently.
• After a short breakin ride, recheck clutch cover bolts and cable free play, and inspect for any leaks.

Why proper installation matters

A correctly installed clutch kit returns the TE310's immediate throttle response and consistent power transfer that enduro riders rely on. Proper plate soaking, correct stacking, undamaged basket/hub splines, and correct cable adjustment prevent premature wear, reduce heat buildup, and ensure clean, predictable shifting whether you're threading technical singletrack or powering out of a rut.

Maintenance tips to extend clutch life

• Avoid prolonged slipping during high-load starts it heats and shorts clutch life.
• Keep oil clean and change it at regular intervals contamination and oxidation accelerate wear.
• Address cable stretch or binding early letting a cable run too loose masks plate wear and can lead to damage.
• Inspect the basket and hub whenever you change plates; fixing notches or splines early prevents repeat plate damage.

Related Shopping Categories

Shop Clutch Kits for a 2009 Husqvarna TE310 Dirt Bike.

Shop Clutch Baskets for a 2009 Husqvarna TE310 Dirt Bike.

Shop Clutch Springs for a 2009 Husqvarna TE310 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2009 Husqvarna TE310 Dirt Bike.

Shop Clutch Covers for a 2009 Husqvarna TE310 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.