Just got my manual clutch kit for my xr50 now I need help installing because there werent any instructions with it.

 

Ok, I had my clutch apart last night to install some heavy springs. Here are a few pics. I`ll try an explain how it all goes together. The first pic is a few steps into the install. Time didn`t allow me to take the whole thing apart.

 

The first thing you got to do is take all the stock stuff off including those two gears.There is a special tool for the clutch nut, But I use screwdriver and a hammer. Now you change out the shift shaft. Take the shift lever off then remove the phillips screw on the top left in the pic and the old shaft should slip right out. Install the new shaft, gears, and bushing. Then it should look something like this pic

 

Slide the new clutch hub on the crankshaft. Make sure the splines on the back of the clutch hub is lined up with the ones on the small gear and push it on until you are sure it is seated all the way. Install lock ring, beveled washer, and nut. Tighten nut

 

Next is to install the small cover. There is a sleeve that goes inside the bearing on the cover. The side with the offset whole faces in. Put on the cover and gasket. Then there is a small spring and a sleeve for it. Install it like in the pic.

 

Next install the seals that go in the side cover. The put this sleeve in the back of the side cover. The tab on it goes in the square opening. Install side cover and gasket.

 

There are two o-rings with the kit. One goes on the dipstick the other were my finger is pointing. Install the return spring and shaft.

 

Install the rest of the parts as shown. Leave the set screw and nut in the center loose for now. Line the spring up and push the shaft in until you see the groove in it through that small hole. Tap the pin in. Now run that set screw in with your fingers until it just barely hits metal the tighten nut. Install the cable.

 

Fill the bike with oil and test the clutch. The set scew may need to be adjusted a little. Then stand back and admire the bling.

 

damn nice post!!!!