How To Install a Clutch Kit on a 2009 Yamaha YZ85 Dirt Bike

How To Install a Clutch Kit on a 2009 Yamaha YZ85

Why Replace the Clutch on a 2009 Yamaha YZ85

The 2009 Yamaha YZ85 is a lightweight motocross machine with a wet multiplate, cableoperated clutch designed for quick power delivery and frequent gear changes. Symptoms that point to a clutch kit replacement include slipping under acceleration, dragging or poor disengagement at idle, inconsistent lever feel, harder-than-normal shifting, or a lever that requires excessive travel. Riding styles common to this displacement aggressive starts, woods or sand sections accelerate wear on friction plates and springs. Replacing the clutch restores throttle response, maximizes power transfer, and returns precise shift quality.

Overview of Clutch Components

• Clutch cover access point and oil seal surface.
• Pressure plate clamps the stack of plates against the hub.
• Clutch springs provide clamp force; weakened springs cause slip.
• Friction plates the wear surface that transmits torque; glaze or thin material reduces grip.
• Steel drive plates transfer torque and resist heat; check for warping.
• Clutch hub & basket center components that hold plates and absorb torque; inspect for notching on basket fingers and worn hub splines.
• Inner hub splines ensure clean, undamaged splines for smooth plate movement.
• Thrust washer & pushrod inspect for wear and smooth travel (cable pushrod engagement on the YZ85).

Prepare the Bike

• Ride bike a short distance to bring oil to operating temperature, then park on a level stand.
• Clean around the clutch cover to prevent contamination when opened.
• For a wet clutch like the YZ85's, you can change the clutch without fully draining the engine oil if you catch spill; however, many techs prefer to drain and replace oil after service. Place a drain pan under the bike and remove the clutch cover bolts evenly.
• Disconnect the clutch cable at the lever to remove tension and ensure slack before opening the cover.

Removing the Old Clutch

• Remove the clutch cover carefully oil will spill. Set cover face down on a clean surface to avoid contaminating the gasket face.
• Loosen the clutch springs in a star pattern to relieve pressure on the pressure plate evenly. Remove springs and retain bolts in order if you plan to reuse hardware.
• Lift the pressure plate off. Note any binding, scoring, or heat discoloration.
• Remove friction and steel plates one at a time, keeping them in order so you can compare thickness and wear pattern. Inspect each friction plate for glazing, thinning, or burnt smell; steel plates should be checked for blueing, warping, or rough edges.
• With plates removed, inspect the clutch basket fingers for notching where plates engage and the inner hub splines for burrs or wear. Run your finger along splines and basket edges roughness or sharp grooves indicate potential need for replacement or filing by a qualified shop.
• Check the thrust washer and pushrod for smooth movement; clean or replace if binding or excessively worn.

Preparing New Parts

• Soak new friction plates in the correct engine oil for at least 15-30 minutes so they are saturated before installation this helps immediate engagement and reduces initial slipping.
• Lightly oil the steel plates and hub splines to ease assembly and prevent dry starts.
• Compare new springs to removed springs. If the kit includes new springs, use them; weaker springs reduce clamp force and cause slip.

Installing the Clutch Kit

• Install plates in the correct sequence typically alternating friction plate then steel plate until the stack is complete. Start with the plate that mates to the clutch hub as on the original stack; follow the same fronttoback order you removed them to preserve engagement characteristics.
• Ensure each plate seats fully in the basket and slides smoothly on the hub splines. Misaligned plates can bind and cause engagement issues.
• Place the pressure plate over the stack and handthread the spring bolts. Tighten springs incrementally in a crisscross/star pattern so the pressure plate compresses evenly.
• Do not overcompress during initial snugging tighten until snug and then give a final even pass to set preload. If your kit includes new spring seats or spacers, install them per kit layout.

Reassembly and Final Checks

• Reinstall the clutch cover using a new gasket if available. Tighten cover bolts evenly in a crossing pattern to seat the cover flat finger tight first, then a final pass. Avoid overtightening bolts.
• Refill engine oil if you drained it. Use the recommended oil type for a wet clutch environment to prevent slipping or drag.
• Refill engine oil if you drained it. Use the recommended oil type for a wet clutch environment to prevent slipping or drag.
• Reconnect the clutch cable and adjust free play at the lever. On the YZ85 cable clutch, aim for a slight amount of free play at the lever pivot not zero. Proper cable tension prevents premature slip and ensures full disengagement.
• Check the cable routing for bends or binding and lubricate the cable if needed. Cable stretch can mimic clutch wear; if adjustment doesn't restore proper lever feel, inspect the cable for fraying or damage.
• If you notice inconsistent lever feel after reassembly, recheck plate seating and spring torque evenly. Air is not a factor in a cable clutch, but contaminated oil or glazed plates will affect engagement.

Test Ride and BreakIn

On a test ride, avoid aggressive launches for the first 20-30 miles. Gradually load the clutch through varied RPM and gear changes to allow the new clutch material to mate to the basket. Expect improved throttle response, crisper shifts, and restored power delivery when the breakin is complete.

Maintenance Tips for 2009 YZ85 Owners

• Frequent short bursts and aggressive starts accelerate plate wear on a motocrossfocused 85cc monitor lever feel often.
• Use oil formulated for wet clutches and change oil regularly; burnt or contaminated oil increases clutch glazing and wear.
• Check cable free play before each ride and inspect the cable for stretch; a binding or frayed cable hides clutch problems and increases wear on the plates.
• Inspect the basket fingers and hub splines each time you change plates early detection prevents costly secondary damage.

Proper clutch installation on the 2009 Yamaha YZ85 brings back crisp engagement and reliable power transfer essential for competitive motocross starts and tight trail work. Follow the steps above, pay attention to cable adjustment and oil condition, and your YZ85 will feel closer to new.

Related Shopping Categories

Shop Clutch Kits for a 2009 Yamaha YZ85 Dirt Bike.

Shop Clutch Baskets for a 2009 Yamaha YZ85 Dirt Bike.

Shop Clutch Springs for a 2009 Yamaha YZ85 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2009 Yamaha YZ85 Dirt Bike.

Shop Clutch Covers for a 2009 Yamaha YZ85 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.