TRIPLE DISK CLUTCH MANUAL KTM 50cc 2009-2012

INSTALLATION STEPS:

INSIDE OF STOCK COVER MUST BE MODIFIED TO ALLOW PROPER CLEARANCE WITH BASKET.1. Remove clutch cover from engine then remove the screw with copper washer from cover2. Apply JB Weld or any metal epoxy to threads of bolt. Reinstall bolt with copper washer. Bolt must bepermanently attached to cover to prevent working loose and leaking oil.3. After epoxy is fully hard grind down the boss that is located on inside of factory cover. Mandatory forclearance with clutch basket.4. Boss must be ground to 3/16” or 4.75MM to allow clearance with basket. Note: Boss is tapered andmust be measured at highest point for proper grind dimension. Next ..Clean grinding grit from coverand insert factory o ring. Note: IRP Billet Cover fits clutch without grinding. P/N 920386

Remove

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Boss

DREMEL

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Note: JB Weld or anysubstitute 2 partmetallic epoxy can befound in most Auto PartsStores or HomeImprovement Stores orHardware StoresGet the Quick HardeningType

2Epoxy threads

5. Remove factory clutch and the two caged bearings … save bearings for later use

6 Place inner spacer P/N 920377 onto inner ring with collar

REMOVE BEARINGS

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Inner spacer

Inner ring with collar

7 Install ONLY ONE of the caged bearings onto inner ring with collar.

8. Install clutch drive assembly onto bearingNote: Teeth must mesh for clutch to go on until it contacts inner spacer see arrow below

ONE BEARING

TEETH MUST MESH

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INNER RINGWITH COLLAR

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Inner spacer

9 Install outer thrust washer P/N 920378 over spline … washer must also go over the inner ring withcollar…

10 Install basket onto spline Note: Align the tabs on the friction discs with the drum slots…. failureto align tabs with basket will not allow basket to fit properly onto spline VERY IMPORTANTTip: lift the tabs and wiggle the basket clockwise and counterclockwise to make it easier to alignfriction disks in basketWhen disks are aligned properly the basket will fit onto the spline of the shaft

11 Apply blue loctite to hex head bolt and install with cone washer and flat washer into shaft. Note:the flat washer and cone washer are made to fit inside the counterbore of the basket..the conewasher helps the bolt from working loose… do not use any substitute with an outside diameterover .785”/19.93MM as it will not fit into the counterbore and the head of the bolt will hit thestock cover…

Tighten the bolt to 18 ft lbs/25Nm … if using impact wrench use the lowest setting …

Proper alignment of tabs in friction disk with basket slots

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Outer thrust washerspline

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12 Option spanner wrench p/n 920219 is helpful to hold drum when tightening or removing boltwhen impact wrench not available

13 Install clutch cover making sure the O ring for the cover is in placeMake sure to put in drain plug and tighten and install brake spring

14 Use kick starter to turn over engine several revolutions to make sure clutch spins freely.If clutch does not spin freely perhaps the basket is rubbing on boss in cover see steps 4 and 5 …Remove cover and look for witness marks and grind more off boss until no rubbing is found..

15 Add 300 ML of clutch oil of your choice Note: This clutch is smaller than the factory clutch therefore

more oil is needed to cover disks properly for maximum heat transfer Oil breaks down and must be replaced aftereach day of racing for best performance.

STALL SPEEDStall speed is the RPM that the clutch locks up solid. In racing stall speed is often referred to “slipping”the clutch. Adjusting the clutch for more slip is actually raising the stall speed. Or when adjusting forless slip the stall speed of the clutch is lowered. The trick is to adjust the stall speed at /or slightlybelow the peak torque of the engine.

The power band of the 50cc 2-cycle engine is very narrow therefore proper clutch adjustment isnecessary for maximum performance. A clutch that locks-up below the power band will cause theengine to bog and performance will be sluggish. A clutch that locks up above the power band is (overslipping). A clutch that is over slipping will cause power to be wasted in the form of heat. Excessiveheat may also warp clutch components or damage engine.

The IRP is engineered from the factory with the stall speed setting at about 9400 rpm that is very closeto optimum with a stock pipe . Big bore or modified engines with aftermarket pipe may require raisingthe stall speed of the clutch.

Spanner

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How to adjust the clutch.

The clutch comes with adjustable retainers installed. Follow the chart below if changing stall speed isnecessary. A tachometer is important to obtain accurate data.

Retainer HeightAPPROXIMATESTALL SPEED

.226”/5.74MM 9,400-9500

.218”/5.53MM 9,500-9600

.210”/5.33MM 9,700-9800

Stall Speed Adjustment

The clutch comes from the factory pre-adjusted at .226” for an approximate stall speed of about 9,400 rpm.This is the best stall speed we have found for good performance. If you want to experiment with stall speedyou can raise or lower stall speed of the clutch. Clutch must be removed from engine for adjustment

For higher stall speed turn all 5 flat head screws clockwise ¼ turn per test session.

For lower stall speed turn all 5 flat head screws counter-clockwise ¼ turn per test session.

Do not exceed adjustment limits below. Note: 1 full turn of the screw is .032” / .81MM

Measure from top of the RETAINER to the top of the drive hub as shown below. (Arrows)

Maximum Limit .230” / 5.84MM Minimum Limit .180” / 4.57MM

This chart is only a guideline. Exact stallspeed adjustment will vary from engineto engine and other factors such airdensity and air temperature. Atachometer must be used to perform anaccurate test.

MaintenanceRacing causes extreme wear and tear on the clutch therefore it is important to inspect clutch for wear after eachracing event.Check all parts for cracks or excessive wear and replace if necessary.Check floaters for warp. Replace if warped or worn more than .005” / .13MM replace. Color brown or blue OKCheck friction disc for wear. Replace when worn below .088” / 2.23MM thick ( Very important)

Made in USA Intuitive Race Products Patent D487,760S

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Item # Part # Description UnitsRequired

1 920379 Bolt M8 x 25 1

2 920202 Cone Washer 1

3 920203 Flat Washer .775” OD 1

4 920381 Basket 1

5 920378 Outer Thrust Washer 1

6 920206 Screw,flat head T-25 Torx 10-32x ½,ea 5

7 920207 Fixed Plate 1

8 920383 Friction Disk, each 3

9 920209 Floater Plate 2

10 920210 Pressure Plate 1

11 920382 Geared drive hub 1

12 920384 Lever, each 5

13 920213 Dowel Pin,each 5

14 920233 Spring,each 5

15 920215 Retainer,each 5

16 920216 Screw, 10-32 x 5/8 Flat head,each 5

17 920377 Inner spacer 1

920219 Clutch Spanner Wrench Optional

920386 Cover, billet with o ring Optional

920387 O Ring , fits billet cover Optional

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920360 Clutch Complete