How To Install a Clutch Kit on a 2020 Suzuki RMZ250 Dirt Bike

How To Install a Clutch Kit on a 2020 Suzuki RMZ250

Why replace the clutch on a 2020 Suzuki RMZ250?

The 2020 Suzuki RMZ250 is a 250cc motocross machine that uses a wet, multiplate, cableactuated clutch designed for aggressive starts and frequent shifting. Over time a clutch will show symptoms such as slipping under load, dragging or sticking between shifts, inconsistent lever feel, hard shifting, or a lever that requires excessive travel. These issues commonly result from worn friction plates, hardened springs, notched clutch basket fingers, or a stretched cable that mimics plate wear. Proper clutch replacement restores crisp throttle response, solid power transfer, and predictable shift quality so your RMZ250 performs the way a motocross bike should.

Tools & prep

• Basic hand tools – sockets, ratchet, screwdrivers, Allen keys
• Torque-capable ratchet or driver (observe your own torque practices)
• Drain pan, clean rags, gasket scraper
• New clutch kit (friction & steel plates, springs, pressure plate if included)
• Fresh crankcase oil & a new drain washer (if you choose to drain oil)
• Clutch cable or replacement parts if cable shows wear
• Small container of appropriate engine oil for soaking plates

Park the bike on a level stand, cool engine, and clean the exterior around the clutch cover to keep dirt out when you open the case.

Preparing the RMZ250 – oil and safety choices

The RMZ250 uses a wet clutch submerged in crankcase oil. You can remove and replace the clutch without fully draining the engine, but draining a portion or the full crankcase oil makes the workspace cleaner and prevents contamination of the new plates. If you drain oil, collect it and refill with fresh oil after reassembly. Remove the seat and right-side plastics for better access, and position the bike on a solid stand to keep it steady.

Remove the clutch cover

Loosen and remove the clutch cover bolts in a crisscross pattern. Pull the cover free; a gentle tap with a rubber mallet may be needed if the gasket is stuck. Keep track of the small dowel pins and the cover's alignment. With the cover off you'll see the pressure plate and external clutch springs.

Disassemble the clutch pack

• Loosen the clutch spring bolts evenly in multiple passes rather than removing one at full torque to avoid spring tension surprises.
• Remove the pressure plate and set aside springs, spring seats, and retainers in order.
• Slide out the friction and steel plates one by one, noting the order & orientation. On the RMZ250 plates alternate between friction and steel plates.

Inspect each friction plate for glazing, thinning, or uneven wear. Steel plates should be checked for blueing or warpage by eye & feel. If steels show discoloration or a burned appearance, replace them. Compare the old plate stack height and count to the new kit to confirm parts match.

Inspect basket, hub & splines

With the plates removed inspect the clutch basket fingers for notching or grooves where the friction plates engage. Check the inner hub splines for wear by sliding a plate onto the spline — it should seat without excessive play. Look at the thrust washer and pushrod (if visible) for scoring or shortening. Moderate wear on friction plates is normal; deep notches, excessive spline wear, or a scored thrust washer usually call for replacement or further service.

Cable checks before reassembly

Because the 2020 RMZ250 uses a cable clutch, examine the cable for fraying or kinks. Check cable routing, and operate the lever to feel for binding. Adjust free play at the lever perch until you have the correct amount of movement that allows full engagement without dragging. A stretched cable can mimic slipping and should be replaced or adjusted as needed.

Prepare new plates

Soak new friction plates in fresh engine oil for at least 15–30 minutes before installation. This helps prevent immediate overheating and clutch chatter on first use. Heat the oil slightly by using engine-temperature oil (cooled but warm is fine) for faster absorption, but avoid open flames or unsafe heating methods.

Reinstall the clutch pack

• Install plates in the correct alternating order – friction then steel, taking care with any stamped orientation marks.
• Ensure each plate fully seats into the basket fingers and inner hub splines as you stack them.
• Replace the pressure plate, springs, and spring seats exactly as removed.
• Tighten spring bolts a little at a time in a crisscross pattern to evenly compress the pack.

Do not overcompress any one spring; even tightening prevents warped pressure plates and uneven wear. Replace springs with the new set from the kit if provided — older springs can reduce clamp load and cause slipping even with new plates.

Reassemble cover, refill oil & final adjustments

Clean the cover and mating surfaces, install a new gasket or carefully reuse the existing one if in good condition, and reinstall the clutch cover bolts. Refill engine oil if you drained it, and run the engine up to operating temperature briefly to circulate oil into the new plates. With the bike off, recheck clutch cable free play at the lever; adjust the perch so there is slight free play but firm engagement. After a short test ride, recheck cable adjustment once plates have seated.

Breakin and performance notes

On the 2020 Suzuki RMZ250 expect a short bedin period where engagement smooths and the lever becomes consistent. Avoid fullthrottle launches for the first few tanks to let friction materials mate to steels. Proper installation returns the signature RMZ250 throttle response – immediate power transfer and reliable shifts during tight woods, sand, or aggressive motocross starts. If you still notice slipping after new parts and correct cable adjustment, doublecheck basket condition and spring clamp load; persistent slipping often points to basket notching or weakened springs rather than plate defects.

Final inspection checklist

• Clutch lever has correct free play and moves smoothly
• No oil leaks at the clutch cover or cable area
• New plates soaked and seated; pressure plate is flat
• Basket fingers and hub splines show no severe damage
• Oil level correct and oil condition clean

Following these steps tailored to the 2020 Suzuki RMZ250's wet, cableactuated clutch will get you back on the track with restored shift feel, dependable power transfer, and confidence during aggressive riding.

Related Shopping Categories

Shop Clutch Kits for a 2020 Suzuki RMZ250 Dirt Bike.

Shop Clutch Baskets for a 2020 Suzuki RMZ250 Dirt Bike.

Shop Clutch Springs for a 2020 Suzuki RMZ250 Dirt Bike.

Shop Inner Hubs and Pressure Plates for a 2020 Suzuki RMZ250 Dirt Bike.

Shop Clutch Covers for a 2020 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.