How To Install a Clutch Kit on a 2017 Suzuki RMZ250 Dirt Bike

How to Install a Clutch Kit on a 2017 Suzuki RMZ250

Why replace the clutch on a 2017 Suzuki RMZ250?

The 2017 Suzuki RMZ250 is a 250cc motocross machine with a cable-operated, wet multi-plate clutch. Typical signs a clutch kit is needed include slipping under hard acceleration, dragging or grabbing during shifts, inconsistent lever feel, hard shifting, or a lever that requires excessive travel to disengage. Aggressive starts, tight woods riding, sand, or high-heat track abuse accelerate wear on friction plates, steel plates, springs, and basket fingers. Replacing the clutch restores direct power transfer, crisp engagement, and predictable throttle response.

Tools, parts & prep

• Clutch kit specific to 2017 Suzuki RMZ250 (friction plates, steels, springs, pressure plate components as applicable)
• Basic hand tools sockets, wrenches, screwdrivers, pliers
• Clutch cable lubricant (if reusing cable) and fresh engine oil for a wet clutch
• Clean rags, drain pan, small brush, gasket or RTV if needed
• Motorcycle stand and stable workspace

Park the bike upright on a stand, warm the engine briefly to thin the oil, then shut it off. For the RMZ250 wet-clutch, drain or change the engine oil if your clutch cover removal requires oil drainage or if the manufacturer recommends fresh oil with a new kit. Clean the area around the clutch cover to keep debris out of the engine.

Remove the clutch cover and access the stack

Loosen and remove the clutch cable from the lever and free the cable at the clutch arm. Remove any small covers or guards blocking the clutch cover, then remove the clutch cover bolts in a crisscross pattern to avoid binding. Carefully separate the cover after confirming no hidden fasteners; a gentle pry with a soft mallet may be needed. Keep note of any gasket material and set bolts aside in order.

Remove springs, pressure plate & plates

On the RMZ250 the clutch springs are typically held by bolts around the pressure plate. Loosen springs gradually in a cross pattern to relieve pressure evenly. Remove the pressure plate and set aside intact springs and pushrod assembly as a set. Pull the friction and steel plates out in sequence note the orientation and order so you can replicate it if desired. Friction plates usually alternate with steels in the stack.

Inspect components & look for trouble

• Friction plates check for glazing, uneven wear, or thinning. Replace if any signs of overheating or smooth, shiny surfaces that reduce grip.
• Steel plates look for heat discoloration, warping, or grooving. Warped steels will cause chatter; replace when they show blueing or severe distortion.
• Clutch basket and hub inspect fingers for notching or groove formation where the plate tabs engage. Light notching is normal, but deep grooves can cause dragging and will shorten the life of new plates.
• Inner hub splines check for burrs or electric-style wear where the basket meets the hub.
• Thrust washer & pushrod ensure the pushrod is straight and washer surfaces are smooth. Check for signs of scoring or uneven wear.
• Clutch cover clean mating surfaces and ensure no metal debris remains inside the case.

If the basket shows heavy notching or hub splines are damaged, consider replacing those parts before installing a fresh kit new plates will wear faster against badly notched parts.

Prepare new plates and reassemble

Soak new friction plates in fresh engine oil for several minutes before installation to ensure immediate lubrication and to prevent early slippage. Lay the plates back in the exact alternating pattern of friction, steel, friction, steel. On the RMZ250 this alternation matters to the engagement quality.

Install the pressure plate carefully over the stacked plates and align any locating tabs or guide dowels. Reinstall clutch springs and tighten bolts evenly in a crisscross pattern until snug tighten progressively so the pressure plate is pulled down flat. Do not rely on a single corner to pull the plate into place.

Reinstall cover, refill oil & cable adjustment

Clean the clutch cover mating surface and replace the gasket or apply a thin bead of appropriate sealant if required. Reinstall the cover and hand-start bolts, then tighten in a star pattern to ensure even seating. Refill the engine with the recommended oil for a wet clutch and run the engine briefly to circulate oil around the new plates.

Because the RMZ250 uses a cable clutch, check free play at the lever and the slack at the clutch arm. Proper free play prevents partial drag and mimics premature wear. Adjust the cable at the lever or the adjuster near the clutch perch to achieve a smooth disengage with a small amount of free play the feel should be consistent and firm. If the cable shows binding, fraying, or excessive stretch, replace it. Lubricate the cable if it moves roughly; improper cable tension can produce symptoms that look like plate wear.

Final checks & test ride

• With the bike on the stand, shift through gears and run the engine to check for smooth engagement and no slipping at higher rpm.
• Confirm there are no fluid leaks around the clutch cover or cable area.
• On a short, controlled ride verify throttle response, shift quality, and lever feel. New plates commonly require a break-in period where feel becomes more solid after a few rides.

Practical riding context

On a 250cc motocross bike like the RMZ250, clutch life depends on riding style. Aggressive starts, frequent slipping in deep sand, or heavy low-speed technical riding increase plate wear. Using the correct oil for a wet clutch and keeping the cable in good condition extend kit life. Proper installation returns predictable power transfer, crisper launches, and cleaner shiftsletting you focus on riding rather than compensating for a tired clutch.

Closing tips

• Keep a clean workspace to avoid contaminating the clutch pack.
• Always replace all friction plates and steels as a matched set when possible.
• If you suspect basket or hub damage, address those before fitting new plates.
• After a new kit install, recheck cable play and fasteners after the first ride.

Related Shopping Categories

Shop Clutch Kits for a 2017 Suzuki RMZ250 Dirt Bike.

Shop Clutch Baskets for a 2017 Suzuki RMZ250 Dirt Bike.

Shop Clutch Springs for a 2017 Suzuki RMZ250 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2017 Suzuki RMZ250 Dirt Bike.

Shop Clutch Covers for a 2017 Suzuki RMZ250 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.