How To Install a Clutch Kit on a 2010 Husaberg FX450 Dirt Bike

How To Install a Clutch Kit on a 2010 Husaberg FX450

Why replace the clutch on your 2010 Husaberg FX450

The 2010 Husaberg FX450 is a high-revving 450cc fourstroke built for aggressive trail and enduro use. Years of tight woods, steep hill starts, heavy sand, or repeated aggressive launches can lead to clutch symptoms like slipping under load, dragging that makes neutral finding difficult, inconsistent lever feel, hard or noisy shifts, and changes in throttle response. Replacing the worn pack restores predictable power transfer, crisp throttle response and consistent engagement so the FX450 behaves like it should on technical terrain.

Clutch system overview for the 2010 Husaberg FX450

The FX450 uses a wet, multiplate clutch actuated by a cable. That means friction plates and steel drive plates sit in oil, and the cable controls pressure plate movement. Before assuming worn plates, check cable free play and inspect for binding. A stretched or sticky cable can mimic a worn clutch by preventing full disengagement or causing inconsistent engagement.

Tools and prep

• Basic hand tools - socket set, ratchet, Allen keys, screwdrivers
• Torque wrench (you will use reference values elsewhere, not provided here)
• Drain pan, clean rags, gasket scraper or new clutch cover gasket
• New clutch kit (friction plates, steel plates, springs if replacing), fresh 10W-40 or recommended oil, and a clean container for soaking plates
• Zip ties or small tag to mark cable routing

Preparing the bike

Park the 2010 Husaberg FX450 on a level stand, cool engine, and secure it so it won't fall. If you ride in dusty environments, clean the clutch cover area to keep debris out when the cover is removed. Because the FX450 clutch lives in the engine oil, you'll drain the oil before opening the cover capture it for proper disposal and replace with fresh oil after reassembly.

Removing the clutch cover and components

• Loosen the clutch cable at the lever and tag the cable to maintain routing. Remove any components that block access to the clutch cover.
• Drain the engine oil and remove the clutch inspection/primary cover bolts. Gently pry the cover free; be ready for residual oil and clean the mating surfaces.
• With the cover off, note the clutch assembly orientation. Loosen the clutch spring bolts in a crisscross pattern a little at a time to relieve pressure evenly. Remove springs, pressure plate and stack.
• Remove friction plates and steel drive plates, keeping their order. Lay them out so you can compare new vs. old and maintain the same installation sequence if reusing any parts.

Inspection what to look for on the FX450

• Friction plates check for glazing, uneven wear, burn marks or ribs worn to the core. Replace if noticeably glazed or thin.
• Steel drive plates look for blue or dark discoloration from overheating and check for warpage by sight. Replace warped or heavily heatmarked plates.
• Clutch basket and hub inspect fingers for notching or grooves where plates catch. Moderate notching causes chatter and accelerated wear; deep notches recommend replacement or dressing.
• Inner hub splines ensure splines are not rounded or excessively worn where the hub rides the transmission input shaft.
• Clutch springs confirm they still have good free length and evenness across all springs. If coils are uneven, replace the set.
• Thrust washer and pushrod check for flatness and free movement; clean off any debris and ensure the pushrod slides smoothly.
• Oil condition contaminated or burnt oil accelerates wear. Note the oil color and smell before refilling.

Soaking new plates and preparing the pack

Because the FX450 uses a wet clutch, soak new friction plates in fresh engine oil for at least 15-30 minutes so they're fully saturated. Steel plates don't need soaking, but wipe them clean. Arrange friction and steel plates in the correct alternating order as you prepare to install the pack.

Reinstalling the clutch pack

• Install plates in the original orientation friction, steel, friction until the stack matches the original height and order.
• Reinstall the pressure plate, then handstart the clutch spring bolts. Tighten springs gradually in a crisscross pattern so the pressure plate comes down evenly.
• Torque bolts to manufacturer recommendations (consult your service guidance) and ensure the pressure plate sits flush without binding.
• Check pushrod alignment and that the thrust washer is correctly seated.

Reassemble cover, refill oil and set cable free play

• Install a new clutch cover gasket or use gasket maker per product instructions, then fit the clutch cover and tighten bolts evenly.
• Refill with the correct grade of fresh oil for the 2010 Husaberg FX450 clean oil improves clutch life and engagement consistency.
• With the engine off, adjust clutch cable free play at the lever to the recommended feel for the bike a small amount of free play prevents drag but ensures full engagement. Inspect the cable for smooth operation and replace if frayed or binding.
• If you notice inconsistent lever feel after installation, recheck spring seating and cable routing. A sticky or kinked cable can make a new clutch feel poor.

Initial breakin and checks

After reassembly, start the engine and let it idle. Test clutch engagement in first and second gear at low speed in a safe area to confirm smooth engagement, no slipping, and consistent lever feel. Expect slightly different feel until plates settle in and oil circulates. Recheck oil level when warm and after the first short ride.

Riding context why correct install matters on the FX450

The 450cc FX450 sees high torque at low revs in technical sections. A properly installed clutch restores crisp launches from tight corners, prevents overheating in sand and mud, and reduces rider fatigue from inconsistent lever pull. Aggressive starts and frequent clutch slipping are the most common causes of premature wear correct installation and fresh oil stop the issue from returning prematurely.

Final inspection and maintenance tips

• Periodically check cable free play and routing for smooth operation.
• Use a quality oil suited for wet clutches and change it at regular intervals to limit contamination and heat buildup.
• Inspect basket fingers and plates when you do major services catching notching early saves time and prevents repeated clutch changeouts.

Related Shopping Categories

Shop Clutch Kits for a 2010 Husaberg FX450 Dirt Bike.

Shop Clutch Baskets for a 2010 Husaberg FX450 Dirt Bike.

Shop Clutch Springs for a 2010 Husaberg FX450 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2010 Husaberg FX450 Dirt Bike.

Shop Clutch Covers for a 2010 Husaberg FX450 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.