How To Install a Clutch Kit on a 2017 Honda CRF250L RALLY Dirt Bike

How To Install a Clutch Kit on a 2017 Honda CRF250L RALLY

Why replace the clutch on your 2017 Honda CRF250L RALLY

The CRF250L RALLY is a 250cc dualsport designed for trail and light enduro use, and its wet multiplate, cableactuated clutch takes a beating from trail starts, frequent slipping in tight woods, and sandy or dusty conditions. Signs you need a clutch kit include slipping under acceleration, dragging when you pull the lever, inconsistent lever feel, hard shifting, or a lever that requires unusual travel to engage. Replacing the clutch restores throttle response, consistent power transfer, and cleaner shift quality.

What you'll need

• CRF250L RALLY clutch kit (friction & steel plates, springs as applicable)
• Basic hand tools sockets, ratchet, screwdrivers, pliers
• Clutch cover gasket or gasket maker
• Fresh engine oil of the correct type for wet clutches
• Clean rags, drain pan, plastic container for old plates
• Service stand or centerstand for stable work

System overview what you'll inspect

The CRF250L RALLY uses a cable clutch that pulls a pressure plate away from a stack of alternating friction and steel plates inside the clutch basket. Key parts to inspect are the clutch cover, pressure plate, clutch springs, friction plates, steel drive plates, clutch hub, clutch basket fingers, inner hub splines, thrust washer and the pushrod. Also check the clutch cable routing and anchor points for wear or binding.

Preparation

• Park the bike upright on a stand and run the engine briefly to warm oil warm oil drains faster and carries debris out.
• Turn the engine off and remove the seat and any bodywork blocking the right side clutch cover.
• Place a drain pan under the engine and loosen the clutch cover bolts. On the CRF250L RALLY you can remove the cover without fully draining the crankcase in some cases, but if you expect to remove many parts or if the service area is dirty, drain oil first to keep things clean.
• Clean the area around the clutch cover to prevent contamination when you open the case.

Removing the clutch

• Remove the clutch cover carefully some oil will escape. Use a clean surface to lay the cover and note the gasket condition.
• Loosen and remove the clutch spring bolts in a crisscross pattern to relieve pressure evenly. Remove the springs and pressure plate.
• Take out the friction and steel plates in sequence. Count and keep the order so you can confirm the new stack matches the same pattern and quantity.
• Remove the inner hub nut or retaining mechanism and slide the hub and plates out as needed to access the basket for inspection.

Inspection what to look for

• Friction plates check for glazing, deep score lines, or excessive wear. Slight darkening is normal; heavy glazing that causes slip indicates replacement.
• Steel plates look for blue discoloration or warping. Warped steels will cause grabbing or chatter.
• Clutch basket fingers inspect for notching at the contact points where plates engage. Severe notching leads to drag and jerky engagement and may require basket replacement.
• Inner hub splines & thrust washer check for rounded teeth or grooving. Play in the hub can cause inconsistent engagement.
• Clutch springs confirm free length and that no spring is noticeably shorter or weak; replace as a set with the kit.
• Pushrod & bearings ensure smooth travel and no scoring on contact surfaces.
• Oil condition dark, gritty oil accelerates wear; replace oil before reassembly if it's contaminated.

Preparing new parts

For wet clutches like the CRF250L RALLY's, soak new friction plates in engine oil for at least 10-20 minutes before installation to reduce initial wear and prevent premature slip. Lay the new steels flat and visually confirm they are free of burrs or distortion.

Reassembling the clutch

• Install the clutch basket and hub components cleanly, making sure splines are aligned and the thrust washer is seated correctly.
• Stack plates in the correct order friction, steel, friction matching the original count. An incorrect sequence can cause poor engagement or inability to shift.
• Install the pressure plate and then fit clutch springs by hand. Tighten spring bolts incrementally in a crisscross pattern to seat the plate evenly.
• Reinstall the clutch cover using a new gasket or gasket maker to prevent leaks. Clean mating surfaces before assembly.
• If you drained oil earlier, refill with the recommended oil for wet clutches; warm the engine and cycle the clutch a few times to distribute oil through plates before riding.

Cable clutch specific checks

Because the 2017 CRF250L RALLY uses a cableoperated clutch, adjust free play at the lever so there is a small amount of movement before the clutch starts to disengage this prevents dragging while ensuring full engagement. Inspect the cable for fraying, kinks, or binding along its routing and lubricate or replace the cable if movement is rough. Cable stretch or incorrect adjuster position can mimic worn plates, so rule out cable issues before concluding extensive clutch damage.

Hydraulic feel & final checks

Even with a cable system, confirm lever feel is consistent and smooth after reassembly. Pull the lever several times to check engagement points and confirm no binding. Check around the slave area and cover for oil leaks. Ride gently for the first few miles to allow plates to bed in, then recheck cable free play and clutch cover fasteners.

Riding context that affects clutch life

On a 250cc dualsport like the CRF250L RALLY, clutch wear accelerates with aggressive launches, repeated lowspeed maneuvering in technical trails, heavy load riding with luggage or a passenger, and prolonged slipping in sand or deep mud. Regular oil changes with a quality oil suitable for wet clutches, proper cable maintenance, and avoiding sustained clutch slip will extend kit life.

Finishing touches

After a short breakin ride, recheck for oil leaks, confirm cable adjustment, and verify smooth shifting through the gearbox. Properly installed clutch components restore crisp throttle response and consistent power transfer exactly what riders expect from a CRF250L RALLY when the trail gets technical.

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Shop Inner Hubs and Pressure Plates for a 2017 HONDA CRF250LR Dirt Bike.

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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.