How To Install a Clutch Kit on a 2018 Suzuki RMZ250 Dirt Bike

How to Install a Clutch Kit on a 2018 Suzuki RMZ250

Why replace the clutch on your 2018 Suzuki RMZ250

The 2018 Suzuki RMZ250 is a 250cc motocross machine that puts heavy demands on a wet multiplate clutch aggressive launches, repeated slipping in tight woods, sand starts and highrpm racing all accelerate wear. Typical symptoms that signal clutch replacement include slipping under load, dragging/poor disengagement, inconsistent lever feel, hard shifts and a loss of crisp throttle response. Replacing worn plates and springs restores power transfer, throttle response and consistent shift quality so the bike behaves predictably on the track or trail.

Clutch system characteristics RMZ250 (2018)

The RMZ250 uses a cableoperated, wet multiplate clutch with friction plates, steel drive plates, clutch basket and inner hub. Because it's cable actuated, cable free play and smooth routing are critical a stretched or binding cable can mimic worn plates. The wet design means new friction plates should be soaked in oil before installation to ensure proper breakin and lubrication.

Tools & basic prep

• Socket set, clutch holding tool or impact driver, screwdrivers, pliers
• Clean rags, drain pan, fresh engine oil and filter if you plan to change oil
• Replacement clutch kit (friction & steel plates, springs, any included hardware)
• Clutch cable lube and a small container for soaking plates

Prepare the bike

Position the RMZ250 on a stable stand with the engine cool. Because the clutch cover sits in the engine oil bath, plan to drain oil either fully or partially depending on how much will spill when the cover is removed. Clean around the clutch cover to prevent dirt falling into the case. Loosen the clutch cable at the lever to remove tension before you begin.

Removing the clutch cover and assembly

• Drain some oil into a pan if needed to reduce spillage when the cover is removed. Remove the clutch cable from the lever and free the cable end from the release arm.
• Remove clutch cover bolts in a crisscross pattern and carefully pull the cover free watch for oil and the release pushrod/thrust washer as you lift it away.
• With the cover off, hold the pressure plate and remove the clutch springs and spring bolts evenly to release tension. Keep springs and bolts in order if reusing.
• Remove the pressure plate and then pull out the friction and steel plates as a stack; note their order and orientation.

Inspection checklist what to look for

• Friction plates: check for glazing, uneven wear, burnt smell or thin liners. Glazed plates often look shiny and smooth.
• Steel drive plates: inspect for heat discoloration, warping or scoring. Slight wear is normal but heavy discoloration or bellmouthing indicates replacement.
• Clutch basket: inspect the basket fingers for notching where plates engage pronounced notches cause drag and chatter.
• Inner hub splines: check for rounded splines or heavy wear where the hub engages the primary drive.
• Springs: compare free length across springs if one spring is noticeably shorter, replace the set. Weak springs cause slipping under load.
• Thrust washer & pushrod: confirm smooth surfaces and that the pushrod moves freely without binding.

Preparing new plates and parts

Soak new friction plates in clean engine oil for at least 10-15 minutes to ensure they are fully saturated. While plates soak, clean the clutch basket, hub, pressure plate and cover mating surfaces. If basket fingers show moderate notching, light filing can smooth edges but significant notching warrants replacement to prevent rapid rewear.

Reassembling the clutch

• Begin stacking plates on the clutch hub in the correct order typically friction plate then steel plate, repeating until full. Ensure each plate seats fully and alternates correctly.
• Install the pressure plate over the stacked plates and fit the clutch springs. Tighten spring bolts in a crisscross pattern a few turns at a time to keep even pressure across the platedo not fully torque to factory spec here, but tighten evenly until snug. Replace spring bolts with new hardware if included.
• Confirm the pushrod and thrust washer are correctly positioned and that the release mechanism moves freely when the lever is actuated at the cover removed stage.

Reinstalling cover, refilling oil & cable adjustment

After assembly, reinstall the clutch cover with a clean gasket surface and evenly tighten bolts. Refill with the correct grade and quantity of engine oil for the RMZ250 fresh oil is important for clutch performance. Reattach and adjust the clutch cable:

• Set initial free play at the lever per a light fingertip movement enough to ensure full engagement at rest but not so much that the clutch drags. Because this bike uses a cable, check for smooth travel and lube or replace a binding cable.
• Operate the lever several times to settle the plates, then recheck oil level and lever free play.

Breakin and final checks

Ride gently for the first sessionshort laps, light acceleration and smooth clutch useto allow plates to seat and oil to circulate. After the initial ride, recheck cable adjustment and inspect for leaks around the clutch cover and slave/release area. Expect improved throttle response, crisper power delivery and smoother shifts once the new clutch is broken in.

Common clutch wear causes for an RMZ250 motocrosser

Aggressive starts, frequent slipping on climbs or in sand, overheating from hard use and incorrect oil can accelerate wear. Regularly checking cable free play and oil condition will extend clutch life between rebuilds but when symptoms appear, a full clutch kit and spring replacement will restore predictable performance for racing or trail abuse.

Related Shopping Categories

Shop Clutch Kits for a 2018 Suzuki RMZ250 Dirt Bike.

Shop Clutch Baskets for a 2018 Suzuki RMZ250 Dirt Bike.

Shop Clutch Springs for a 2018 Suzuki RMZ250 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2018 Suzuki RMZ250 Dirt Bike.

Shop Clutch Covers for a 2018 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.