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TSM Tech – Clutch Removal And Installation

by Charles Owens on 11/28/2012

Clutch Removal And Installation

This information is good for most motocross and off-road applications.

Basic Tools Required (In most cases)

We used a Complete Wiseco Clutch Kit that included the Clutch and Friction plates as well as new springs.

We used a Wiseco Clutch Kit and Boyesen Clutch Cover on our KX 125

The first thing you should do (the day before you plan to do your installation), Soak your friction plates in Transmission Oil for 6-12 hours. There is a lot of debate about this, and even some say you can run them dry. We always soak ours, usually overnight.

Before you begin any work on your bike, clean your work area and the bike itself. Especially the area you plan to be working on. (In this case scrub and spray heavily around the motor and clutch cover area.)

Put your bike on its stand and drain the oil as usual. We always remove the rear brake lever and let it hang from the master cylinder, out-of-the-way.

Remove the 8mm bolts holding the clutch cover on, keep your drain pan close by. If the cover has been on for a while it may need a small tap with a rubber hammer to loosen it up.

Now you have access to the clutch assembly. Remove the five 10mm bolts holding the clutch assembly together. These bolts may be under slight pressure from the clutch springs.

Clutch Pressure Plate exposed after cover removal

Remove the Clutch Pressure Plate and inspect it for damage, if it looks ok set it aside. You can remove the friction/clutch plates individually or all together. Once the plates are removed, inspect your Clutch Hub and Basket for excessive wear and damage.

Make sure your gasket mating surfaces are clean and all of the old gasket material is removed. Be sure not to gouge the case surfaces.


Installation is just as easy. Start by inserting one of your pre-soaked friction plates, alternating them with the steel plates.The Friction plates have wide ‘teeth’ on the outside that slide into the grooves of the basket. The Steel Plates will have smaller ‘teeth’ that slide over the Clutch Hub.

If installed correctly you will have a friction plate first to mesh with the Clutch Hub and a friction plate last to mesh with the Clutch Pressure Plate.

Install the Clutch Pressure Plate over the assembly and insert the five new springs. Insert the five 10mm bolts and torque them to your manufacturers specification. Be sure not to overtighten them.

With your case surfaces cleaned and prepped install the new clutch cover gasket(some cases will have alignment pins to make this easier) Install the clutch cover making sure the gasket stays in place as you insert the 8mm bolts. Torque them to your manufacturers specification.

(In our case we installed the Boyesen Clutch Cover, for this the two alignment pins need to be removed from the case.)

Re-install the rear brake lever(if removed.) Re-fill with your favorite brand of Transmission Oil to the manufacturers recommended capacity.

Once everything is finished, double check your work and GO RIDE!