How To Install a Clutch Kit on a 2020 Honda CRF250L ABS Dirt Bike

How To Install a Clutch Kit on a 2020 Honda CRF250L ABS

Why replace the clutch on a 2020 CRF250L ABS?

The 2020 Honda CRF250L ABS is a 249cc dualsport designed for trails and street riding. Its wet, multiplate clutch and cable actuation are built for low weight and predictable engagement, but wear shows up as slipping under load, dragging/poor disengagement, inconsistent lever feel, hard shifting, or a lever that needs unusual travel to engage gears. Replacing a worn clutch restores direct throttle response, clean power transfer and crisp shifts important whether you're trailriding tight woods, dragging through sand, or commuting.

Know the system what you'll inspect

• Clutch cover - access point and gasket sealing surface.
• Pressure plate - holds plates under spring tension; check for scoring.
• Clutch springs - free length & evenness between springs affects bite.
• Friction plates - look for glazing, thinning, or burnt surfaces.
• Steel drive plates - check for heat discoloration and warpage.
• Clutch hub & basket - inspect for notching, burrs and worn splines.
• Inner hub splines - ensure plates slide smoothly on the hub.
• Thrust washer & pushrod - check smooth operation of release mechanism.

Tools & prep

Gather common hand tools, a soft mallet, a parts tray, fresh engine oil that matches CRF250L recommendations, a new clutch kit, replacement gasket or RTV for the cover, and a clutch cable if worn. Work on a level surface with the bike securely supported. Because the CRF250L uses a wet clutch, plan to drain or catch oil when removing the cover cleaning the cover exterior first keeps contamination out of the clutch area.

Stepbystep removal

• Position & drain - Place a drain pan under the engine. Remove the drain bolt and catch oil if cover removal requires it; some riders remove the cover with minimal oil loss by tipping the bike slightly and being ready with absorbent cloths.
• Remove cover - Loosen and remove clutch cover bolts progressively to avoid distorting the case. Pull the cover straight out; you may need to pry gently at the gasket surface. Watch for any loose parts or springs behind the cover.
• Release springs - With the cover off, loosen the clutch spring bolts evenly in a star pattern so the pressure plate comes free without binding. Remove springs and pressure plate; keep bolts and springs organized by location.
• Remove plates - Pull friction and steel plates out one at a time, noting the order. The CRF250L stacks alternating friction and steel plates; preserve the order for reference even though new kit will replace them.
• Check hub & basket - Rotate the clutch basket and inspect the outside fingers for notching where the plates engage. Run a finger along inner splines for burrs. If you find severe notching, it will produce dragging or uneven release and should be serviced.
• Inspect steels & frictions - Hold friction plates up to light; glazing or thinning is a sign to replace. Steel plates with blueing, heavy scoring or warpage should be replaced. Do not rely on guessing thickness; replace visibly damaged or heavily discolored steels.

Preparing the new clutch

New friction plates for the CRF250L must be soaked in the same engine oil you'll use for the bike. Submerge frictions for at least 15-30 minutes to ensure oil penetration. While soaking, clean the basket, hub, pressure plate face, thrust washer and release mechanism with lintfree cloths; remove any deposits or metal debris from the old plates.

Installation reassembly

• Install plates in order - Reinstall the plates starting with the inner friction plate against the hub, alternating friction and steel plates until the stack is complete. Ensure each plate seats fully into the basket grooves and slides on the hub splines without binding.
• Thrust washer & pushrod - Confirm the thrust washer is present and correctly positioned on the pushrod. The pushrod should move freely when you operate the clutch lever; check for smooth travel before final assembly.
• Pressure plate & springs - Fit the pressure plate evenly over the stack. Install springs and tighten their bolts gradually in a crisscross pattern so preload is uniform. Tighten to a snug feel without overcompressing; do not invent torque values.
• Replace gasket & cover - Clean the cover mating surface. Replace the gasket or apply a thin bead of appropriate sealant where required. Fit the clutch cover and tighten bolts progressively to seat it evenly.
• Refill oil - If you drained oil, refill with fresh oil of the correct grade and capacity for the CRF250L. Run the engine briefly and recheck oil level once warm, topping to the correct mark.

Final clutch adjustments & checks (cable clutch specifics)

The 2020 CRF250L uses a cableoperated clutch check free play at the lever first. With the engine off, measure lever free play at the end of the lever and set to a small, perceptible amount of movement before the clutch begins to disengage. Inspect the cable for smooth operation along its routing and look for kinks, fraying or binding at the lever and clutch arm; replace the cable if it hangs or resists. Because cable stretch can mimic plate wear, adjust free play after the new plates are seated.

Breakin and test riding

After reinstalling everything, start the bike and test clutch engagement at low RPM in neutral, then take a short ride with gentle clutch use for the first few miles to help the new plates bed in. Listen for unusual noises, check for oil leaks around the cover, and recheck lever free play after initial heat cycles. Properly installed, the new clutch should restore crisp shifts, predictable engagement and full throttle transfer to the rear wheel.

When to seek help

If you find severe basket finger notching, stuck splines, a damaged pushrod, or persistent slipping after installing a new kit or if the clutch lever behaves inconsistently after adjustment a professional inspection will prevent repeat failures and ensure longevity.

Wear patterns & riding context

On a 250cc dualsport like the CRF250L, clutch life reflects your riding style. Aggressive launches, frequent lowspeed trail work, sand or highload hill climbs produce accelerated wear. Heat and improper oil choice shorten life as well. Replacing the clutch and restoring correct cable tension gets you back to predictable power delivery and better control on technical trails and street sections alike.

Related Shopping Categories

Shop Clutch Kits for a 2020 Honda CRF250L ABS Dirt Bike.

Shop Clutch Baskets for a 2020 Honda CRF250L ABS Dirt Bike.

Shop Clutch Springs for a 2020 Honda CRF250L ABS Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2020 Honda CRF250L ABS Dirt Bike.

Shop Clutch Covers for a 2020 Honda CRF250L ABS 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.