How to Install a Clutch Kit on a 2015 KTM 500XCW

Shop parts for a 2015 KTM 500XCW Dirt Bike.

Why replace the clutch on your 2015 KTM 500XCW?

The 2015 KTM 500XCW is a high-torque enduro machine that sees hard launches, technical trail work, and extended high-load riding. A worn clutch shows up as slipping under acceleration, dragging when releasing the lever, inconsistent lever feel, hard or missed shifts, and intermittent engagement. Replacing the wet multiplate clutch restores direct power transfer, crisp throttle response and predictable shift quality critical for competitive enduro or aggressive trail riding.

Overview of the 2015 KTM 500XCW clutch system

This model uses a cableoperated, wet multiplate clutch with a clutch basket, inner hub, friction plates, steel drive plates and clutch springs. Because it's cable actuated, poor cable adjustment or a binding sheath can mimic worn plates; check the cable as part of diagnosis. The wet design means plates are lubricated with engine oil, so new friction plates should be soaked briefly before assembly.

Tools & prep

  • Metric sockets and ratchet, spline or impact tool for clutch nut if needed
  • Screwdrivers, pliers, soft mallet
  • Torque wrench for general fasteners (avoid fabricating torque values)
  • Clean drain pan, rags, parts tray
  • Fresh oil and filter if you'll drain the crankcase oil
  • Cable lube and light grease

Prepare the bike

  • Park the bike upright on a stand and let the engine cool.
  • Clean the area around the clutch cover to prevent contamination when opened.
  • If you prefer, drain the right-side engine oil many technicians remove the clutch cover with oil in place, but draining reduces spills. Capture oil in a pan.
  • Disconnect the clutch cable at the lever to relieve tension and free the actuator arm.

Removing the clutch cover & inner parts

  • Loosen and remove the clutch cover bolts, staggering removal to avoid warping. Tap the cover gently with a soft mallet if it's stuck; don't pry aggressively.
  • With the cover off you'll see the pressure plate and springs. Mark the spring locations or take a photo to preserve orientation.
  • Loosen the spring bolts in a crisscross pattern, a little at a time, to gradually release pressure. Remove the pressure plate.
  • Pull out the clutch pack friction plates and steel plates noting the order. Keep plates stacked as removed so you can confirm the sequence.
  • Remove the inner hub assembly to inspect the hub splines and basket. Depending on the model, you may need to remove a retaining nut or snap ring.

Inspection checklist what to look for

  • Friction plates: check for glazing, burning, or excessive thinning. Glazed plates look shiny and smooth rather than textured.
  • Steel drive plates: look for blueing, discoloration, or warping. Slight discoloration from heat is common; severe warping causes chatter.
  • Clutch basket: inspect the inner fingers for notching or grooves where plates engage. Notched fingers cause grabby engagement and may require replacement.
  • Inner hub splines: check for wear or rounding where the plates ride.
  • Springs: confirm even free length across springs and look for corrosion or weakness. Replace springs in sets if any show fatigue.
  • Thrust washer, pushrod and bearing surfaces: ensure smooth surfaces and no scoring that would affect release or engagement.
  • Oil condition: dark, burnt smelling oil accelerates clutch wear; note this when deciding to change oil and filter.

Preparing new parts

  • If you're installing a wet-clutch kit, soak the new friction plates in fresh engine oil for at least 15-30 minutes to ensure proper saturation.
  • Lay out the new plates and steels in the correct alternating order before assembly.
  • Lightly grease the hub splines and any bearing surfaces where parts rotate or slide.

Reassembly getting the stack right

  • Install the inner hub and ensure the pushrod/thrust washer are correctly positioned.
  • Reinstall plates in the correct order friction then steel then friction, etc. The basket and hub teeth will index plates; they must sit flush without forcing.
  • Replace the pressure plate and start spring bolts by hand. Tighten springs evenly in a crisscross pattern to seat the plate squarely.
  • Do not overtighten springs; snug them progressively until all are seated, then finalize tightness uniformly.
  • Reinstall the clutch cover with a clean gasket or reusable seal surface. Tighten cover bolts progressively and evenly.

Finishing steps cable adjustment & oil

  • Refill engine oil if drained and replace the oil filter if applicable. Use the oil grade recommended for your riding conditions and the type required by the 500XCW.
  • Reconnect the clutch cable and set free play at the lever per typical cableoperated clutch practice a small amount of free play at the lever ensures full engagement and prevents dragging. Check the cable for smooth travel and lube or replace if stiff.
  • If lever feel is inconsistent after assembly, recheck spring seating and plate order; air or trapped debris can cause uneven engagement.

Break-in and test ride

After installation, run the engine briefly at idle to circulate oil through the clutch stack. Take a short, gentle test ride to bed-in the platesavoid high-load launches for the first few rides. Expect improved throttle response and firmer, more consistent engagement once the plates settle in.

Riding conditions that speed clutch wear

A 500cc enduro engine generates significant heat and torque, so aggressive motocross starts, repetitive slipping in tight woods, sand riding and high ambient temperatures all increase wear. Incorrect oil type or extended oil-change intervals also reduce clutch life. Regular inspection lets you catch glazing and basket notching before they damage new plates.

Final tips

  • Keep track of plate order and spring orientation with photos during disassembly.
  • If basket fingers show notching, replacing just the plates won't fully restore smooth engagement evaluate basket replacement when notching is present.
  • Always use new springs with a clutch kit when provided; uneven spring force is a common cause of grabbing or slipping.

Related Shopping Categories

Shop Clutch Kits for a 2015 KTM 500XCW Dirt Bike.

Shop Clutch Baskets for a 2015 KTM 500XCW Dirt Bike.

Shop Clutch Springs for a 2015 KTM 500XCW Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2015 KTM 500XCW Dirt Bike.

Shop Clutch Covers for a 2015 KTM 500XCW 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.