How To Install a Clutch Kit on a 2011 Yamaha YZ85 Dirt Bike

How To Install a Clutch Kit on a 2011 Yamaha YZ85

Why replace the clutch on a 2011 Yamaha YZ85?

The 2011 Yamaha YZ85 is a lightweight motocross machine with a wet, multiplate, cableoperated clutch. Common symptoms that justify a clutch kit replacement include slipping under acceleration, dragging or incomplete disengagement, inconsistent lever feel, hard or missed shifts, and a generally mushy or overly stiff lever. Riding styles typical to a smallbore motocross bike aggressive launches, tight technical tracks and sand or deep loam accelerate wear on the friction plates and pressure springs. Replacing the clutch restores crisp throttle response, reliable power transfer and predictable shift quality.

Tools, parts & prep

• New clutch kit (friction plates, steel drive plates, springs, any included thrust washer/pushrod pieces)
• Basic hand tools: sockets, ratchet, torque wrench (for general fasteners), clutch holding tool or soft punch, pliers
• Clean rags, parts tray, fresh engine oil compatible with twostroke wet clutch service
• Shop stand and a clean workspace

Park the bike upright on a stand, cool engine temperature, and remove the seat/side panels for access. The YZ85 uses a cable clutch inspect the cable routing and lever before starting. If you choose to drain oil for a cleaner job, collect and dispose properly; new friction plates are best installed in clean oil or soaked prior to use.

Initial inspection & cable check

Before opening the clutch, check cable free play at the lever and for any visible fraying or binding along the routing. Improper cable tension or a binding cable can mimic worn clutch plates by preventing full engagement or disengagement. Adjust cable free play to see if symptoms improve if not, proceed with a full clutch inspection and replacement.

Removing the clutch cover

• Loosen and remove the clutch cover bolts in a crisscross pattern to avoid warping the cover. Keep bolts indexed so they return to their original holes.
• Carefully pull the cover away; some oil may drip. Use a clean rag to keep dirt out of the engine.

With the cover off you'll see the pressure plate, spring set and the stack of friction and steel plates in the clutch basket.

Disassembling the clutch pack

• Loosen and remove the clutch springs evenly remove them in stages to relieve pressure slowly.
• Remove the pressure plate and note its orientation. Keep springs and screws together so you can reinstall without mixing parts.
• Slide out the friction plates and steel drive plates one at a time. Count and record the order so the new plates go back in correctly.

Inspect each removed component as you go.

What to inspect

• Friction plates look for glazing, uneven wear, burned surfaces or excessive thinning. Glazed plates are often shiny and may slip under load.
• Steel drive plates check for blueing, heat discoloration or warping. Run each plate on a flat surface to detect any wobble.
• Clutch basket inspect the basket fingers for notches or grooves where plates engage; notching causes grabbing or inconsistent engagement.
• Clutch hub and inner splines check for rounded or worn splines that allow plates to shift or bind.
• Thrust washer and pushrod ensure smooth surfaces and no excessive play. Replace any scored or damaged pieces included in the kit.
• Springs compare free length and visual condition to new springs; weak or uneven springs lead to slipping under load.
• Oil condition dark, burnt oil can accelerate clutch wear; plan to replace oil after reassembly if you drained or contaminated it.

Preparing new plates

If your YZ85 clutch is a wet type as it is soak the new friction plates in fresh oil for at least 20-30 minutes before installation so they're fully saturated. This prevents initial slippage and helps consistent breakin. Keep steel plates and other parts clean and free of debris.

Reassembling the clutch

• Install the clutch pack in the proper sequence typically alternating friction plate then steel plate finishing with the plate that the pressure plate bears on (match the order you recorded).
• Ensure each plate seats fully into the basket notches and onto the hub splines. Rotate the assembly by hand to confirm smoothness and that no plate is catching on a notch.
• Replace the pressure plate and reinstall springs fingertight, then tighten evenly in a crisscross pattern to seat the plate progressively.

Do not assume springs are identical across kits keep the replacements from the kit matched and installed according to the kit's layout.

Final assembly & cable adjustment

• Clean the mating surface of the clutch cover and reinstall. Tighten bolts evenly to prevent leaksavoid overtightening.
• Refill engine oil if you drained it. Use oil appropriate for a twostroke wet clutch environment if applicable to your engine design.
• Adjust clutch cable free play to a small amount of lever play at the perch per your preferred feel. Check for smooth lever travel and full engagement/disengagement while the engine is off by shifting through gears.

Breakin and validation

Start the bike and let it idle briefly, then test clutch engagement in first gear at low speed in a safe area. Avoid aggressive launches for the first ride to allow plates to mate properly. Expect improved throttle response, firmer engagement and cleaner shifts when installation and plate condition are correct.

Contextual tips for YZ85 riders

• Aggressive motocross starts and hill launches on a YZ85 wear the small clutch pack faster than casual trail use.
• Riding in sand or deep loam increases clutch slippage from added load and heat inspect plates more frequently if you ride these conditions often.
• Regular oil changes preserve clutch life; burnt or contaminated oil shortens plate life and causes inconsistent engagement.

Closing notes

Replacing the clutch kit on a 2011 Yamaha YZ85 is straightforward for a rider with basic to intermediate mechanical skills when approached methodically. Inspect the basket and hub carefully, soak new friction plates, reinstall evenly and confirm proper cable free play. When done right, a fresh clutch kit returns the quick throttle response and clean shifts this lightweight motocrosser was designed to deliver.

Related Shopping Categories

Shop Clutch Kits for a 2011 Yamaha YZ85 Dirt Bike.

Shop Clutch Baskets for a 2011 Yamaha YZ85 Dirt Bike.

Shop Clutch Springs for a 2011 Yamaha YZ85 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2011 Yamaha YZ85 Dirt Bike.

Shop Clutch Covers for a 2011 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.