FOR VIDEO INSTRUCTIONS GO TO P.N IRP TRIPLE GRIP CLUTCH MANUAL KTM 50cc

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1 P.N IRP TRIPLE GRIP CLUTCH MANUAL KTM 50cc INSTALLATION STEPS: Optional Clutch Cover 9039 available wider for more oil capacity no grinding required INSIDE OF STOCK KTM COVER 009- MUST BE MODIFIED TO ALLOW PROPER CLEARANCE WITH BASKET KTM CLUTCH COVER does not require grinding.. Remove clutch cover from engine then remove the screw with copper washer from cover ONLY Apply JB Weld or any metal epoxy to threads of bolt. Reinstall bolt with copper washer. Bolt must be permanently 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 for clearance with clutch basket. Warning!! Cover is magnesium and grinding dust can ignite, wear welding gloves and eye protection. Grind in open area for safety. 4. Boss must be ground to 3/6 or 4.75MM to allow clearance with basket. Note: Boss is tapered and must be measured at highest point for proper grind dimension. Next..Clean grinding grit from cover and insert factory O ring. Note: IRP Billet Cover fits clutch without grinding. P/N Epoxy threads Remove Note: JB Weld or any substitute part metallic epoxy can be found in most Auto Parts Stores or Home Improvement Stores or Hardware Stores Get the Quick Hardening Type 3 DREMEL FOR VIDEO INSTRUCTIONS GO TO Intuitive Race Products Vista California Boss 4 P

2 5. Remove factory clutch and the two caged bearings save bearings for later use 5 REMOVE BEARINGS 6. Place inner spacer P/N onto inner ring with collar. 6 Factory Inner ring with collar IRP Inner spacer P

3 7. Install ONLY ONE of the caged bearings onto factory inner ring with collar. 7 Inner spacer ONE BEARING INNER RING WITH COLLAR 8. Install clutch drive assembly onto bearing Note: Teeth must mesh for clutch to go on until it contacts inner spacer see arrow below 8 TEETH MUST MESH P3

4 9. Install outer thrust washer P/N over spline washer must also go over the inner ring with collar 9 Outer thrust washer spline 0 Install basket onto spline Note: Align the tabs on the friction discs with the drum slots. failure to align tabs with basket will not allow basket to fit properly onto spline VERY IMPORTANT Tip: lift the tabs and wiggle the basket clockwise and counterclockwise to make it easier to align friction disks in basket When disks are aligned properly the basket will fit onto the spline of the shaft 0 Proper alignment of tabs in friction disk with basket slots Cone washer 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 cone washer helps the bolt from working loose do not use any substitute WASHER with an outside diameter over.785 /9.93MM as it will not fit into the counterbore and the head of the bolt will hit the stock cover Tighten the bolt to 8 ft lbs/5nm if using impact wrench use the lowest setting P4

5 Option spanner wrench p/n 909 is helpful to hold drum when tightening or removing bolt when impact wrench not available Spanner ADD OIL STEP 5 3 Install clutch cover making sure the O ring for the cover is in place Make sure to put in drain plug and tighten and install brake spring 4 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 KTM Cover Add 300 ML of IRP NYTRO Clutch Oil. Note: This clutch is smaller than the factory clutch therefore more oil is needed to cover disks properly for maximum heat transfer Cover is deeper and requires 350 ML of oil or 0 ounces. We advise using the IRP Nytro Clutch Lubricant for best hole shots and heat resistance to prevent smoking off. A good quality semi-synthetic AFT will also work. Do not use 75W gear oil or pure synthetic oil! as performance will be compromised. STALL SPEED Stall 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 for less slip the stall speed of the clutch is lowered. The trick is to adjust the stall speed at /or slightly below the peak torque of the engine. The power band of the 50cc -cycle engine is very narrow therefore proper clutch adjustment is necessary for maximum performance. A clutch that locks-up below the power band will cause the engine to bog and performance will be sluggish. A clutch that locks up above the power band is (over slipping). A clutch that is over slipping will cause power to be wasted in the form of heat. Excessive heat may also destroy friction disks, warp clutch components or damage engine. The IRP clutch is engineered from the factory with the stall speed setting at about rpm that is very close to optimum with a stock pipe. Install the IRP clutch with the factory setting before making any changes. This will give you a baseline to work from. P5

6 How to adjust the clutch. The clutch comes with adjustable retainers installed. Follow the chart below if changing stall speed is necessary. A tachometer is mandatory to obtain accurate data. Retainer Height APPROXIMATE STALL SPEED.6 /5.74MM 9, /5.53MM 9, /5.33MM 9, This chart is only a guideline. Exact stall speed adjustment will vary from engine to engine and other factors such air density and air temperature, carburetor adjustment and exhaust system design. A tachometer must be used to perform an accurate test. Stall Speed Adjustment The clutch comes from the factory pre-adjusted at.8 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 speed you 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: full turn of the screw is.03 /.8MM Measure from top of the RETAINER to the top of the drive hub as shown below. (Arrows) Maximum Limit.30 / 5.84MM Minimum Limit.80 / 4.57MM Maintenance Racing causes extreme wear and tear on the clutch therefore it is important to inspect clutch for wear after each racing event. Check all parts for cracks or excessive wear and replace if necessary. Check floaters for warp or worn more than.005 Color brown OK but this indicates running oil level too low or improper oil. Check friction disc for wear. Replace when worn below.088 /.3MM thick ( Very important) P6

7 Made in USA Intuitive Race Products Patent D487,760S Item # Part # Description Units Required Bolt M8 x Cone Washer Flat Washer.775 OD Basket Outer Thrust Washer Screw,flat head T-5 Torx 0-3x ½,ea Fixed Plate Friction Disk, carbon fibre each Kit, Rebuild 3x(90383) x(9009) 5x(9033) Optional Floater Plate Pressure Plate 9038 Geared drive hub Lever, each Dowel Pin,each Spring,each Retainer,each Screw, 0-3 x 5/8 Flat head,each Inner spacer 909 Clutch Spanner Wrench Optional Cover, billet with o ring Optional O Ring, fits billet cover Optional IRP Nytro Clutch Lubricant qt Optional P7

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