How To Install a Clutch Kit on a 2016 KTM 500XCW Dirt Bike

How To Install a Clutch Kit on a 2016 KTM 500XCW

The 2016 KTM 500XCW uses a wet, multiplate hydraulic clutch that's built for hard enduro and offtrail use. Over time aggressive launches, frequent lowspeed technical riding and high heat can cause slipping, inconsistent lever feel or dragging. Replacing the clutch kit restores throttle response, clean power transfer and positive shift feel and the following stepbystep walkthrough gets a rider with basic to intermediate mechanical skill through the job confidently.

Why replace the clutch?

• Clutch slipping under load loss of drive at high RPM or when accelerating hard.
• Dragging or poor engagement bike creeps in gear, or requires extra lever pull to disengage.
• Inconsistent lever feel spongy or varying resistance, often with hydraulic systems due to fluid or wear.
• Hard or crunchy shifts glazed friction plates or warped steels reduce smooth engagement.

Preparation

• Warm the bike briefly, then place it on a stand so the suspension is unloaded and the wheels can be rotated if needed.
• Gather a new clutch kit (friction plates, steel plates, springs and any supplied hub washers), clean rags, the correct oil for the engine, a drain pan, basic hand tools, and a small container for used parts.
• Because the 500XCW has a wet clutch inside the crankcase area, plan to drain oil or be prepared to change it after reassembly old oil means contaminants and reduced clutch life.
• Disconnect the battery for peace of mind while working on the clutch area if desired.

Remove clutch cover and expose the pack

Clean the outside of the clutch cover to keep debris from falling in. Remove the cover bolts evenly. With a hydraulic clutch there's no external cable, but note the pushrod and slave area when pulling the cover inspect for oil seepage or obvious leaks while the cover comes off. Set the cover aside and keep the gasket surface clean.

Disassemble the clutch stack

• Loosen the clutch pressure assembly evenly in a crisscross pattern so springs release gradually. Remove pressure plate, springs and spring retainers.
• Pull out the friction and steel drive plates in their installed order. Keep them stacked or labeled so you don't mix orientation when comparing old vs new.
• Inspect the thrust washer and pushrod confirm smooth travel and no scoring. If the pushrod rides on a small bearing or washer, note its condition for replacement if grooved.

Component inspection what to look for

• Friction plates check for glazing (shiny, hard surface), uneven wear, or missing friction material. Light surface darkening is normal; deep grooves or thin liners mean replacement is necessary.
• Steel plates look for blueing or discoloration and check for warpage by laying on a flat surface and rocking. Strong heat spots or distortion indicate replacement.
• Clutch basket and hub inspect basket fingers for rounded edges or notching where plates engage. Notched fingers cause grabby engagement and will accelerate plate wear.
• Inner hub splines confirm the splines aren't heavily rounded or chipped. Spline wear causes slop and uneven engagement.
• Clutch springs compare free length to the unused set any visibly shorter or sagged springs should be replaced. Replace springs in sets to preserve even pressure.
• Cover and thrust surfaces clean and inspect the pressure plate contact faces. Ensure the clutch cover mating surface and gasket groove are free of burrs.

Prepare new plates

Soak the new friction plates in fresh engine oil for at least 10-15 minutes before installation so they're fully saturated. This reduces initial slippage and wear. Keep new steel plates dry until the friction plates are ready to ensure correct seating order.

Reassemble the clutch pack

• Install plates in the correct alternating order friction, steel, friction, steel starting with the first plate that goes on the hub. Pay attention to any marked plates from the kit for correct placement.
• Ensure each plate seats fully into the basket fingers and slides freely on the hub splines. Rotate the stack slightly as you assemble to align teeth and seat plates properly.
• Install the pressure plate and compress springs evenly. Tighten the spring bolts gradually and evenly in a crisscross pattern so the plate remains flat as it compresses.
• Confirm the pushrod and thrust washer are correctly positioned and move freely when the lever is operated (with the cover off you can check travel by pulling the lever or actuating the master cylinder).

Clutch cover and oil

Clean the cover sealing surface and install a new gasket or carefully reuse a reusable gasket if in good condition. Refit the clutch cover bolts in a cross pattern and snug them progressively. Refill the engine with the correct fresh oil and a new filter if you drained the case clean oil helps clutch life and smooth engagement.

Hydraulic system check & lever feel

Because the 2016 KTM 500XCW uses a hydraulic clutch, check the lever for consistent feel and travel. Inspect the slave cylinder area near the clutch cover for any seepage. If the lever is spongy or inconsistent after assembly, air in the system can affect engagement a short bleed to remove trapped air will restore crisp operation.

Final checks and breakin

• With the bike still on the stand, shift through gears to verify smooth engagement and that the clutch fully releases. Rotate the rear wheel slowly while in gear to confirm there's no unexpected drag.
• Start the engine and let it idle while checking for leaks around the cover and hydraulic fittings.
• Ride gently for the first 10-20 minutes to bed in the new plates avoid repeated aggressive launches during initial breakin so the linings seat evenly.

Troubleshooting quick tips

• Feeling slippage after a short ride check oil condition and confirm plates were soaked before install.
• Grabby or notchy engagement inspect basket fingers for notching and replace if necessary.
• Soft or inconsistent lever inspect for hydraulic leaks and bleed the system if air is suspected.

Properly replacing the clutch on a 2016 KTM 500XCW returns the direct power delivery and reliable engagement expected from a 450+cc enduro machine. With careful inspection of the basket, hub, plates and springs, and attention to hydraulic lever feel, you'll restore confident throttle control and crisp shifting for demanding trail and enduro conditions.

Related Shopping Categories

Shop Clutch Kits for a 2016 KTM 500XCW Dirt Bike.

Shop Clutch Baskets for a 2016 KTM 500XCW Dirt Bike.

Shop Clutch Springs for a 2016 KTM 500XCW Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2016 KTM 500XCW Dirt Bike.

Shop Clutch Covers for a 2016 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.