Pit Bike Shipping INFO
Pit Bike Set Up INFO
Pit Bike Starting Info
GENERAL PIT BIKE SIZE & USAGE GUIDE
SSR Owners Manual
The Model Year Myth
Dealer Prep that T Bolt USA does NOT Charge you
Cradle Frame Advantage
Pit Bike Size Comparison
Basic Pit Bike Wiring
Wiring With Lights
Japan Inner Rotor Kit
China Inner Rotor Wiring
Lifan Outer Rotor Wiring (Daytona Style)
155cc or 155Z wiring
Wires you likely wont need
Testing Electrical Systems & components
How to Remove & Replace a Broken stator
Pit bike engine wiring and Chassis wiring systems
Honda XR/CRF50 & 70 Wiring
Drive Chain info
Testing Wheel Bearings
How To Bleed Brakes On Your Dirt Bike
Pit bike Oil level check
Pit bike Oil Change Info
Pit bike Oil Filter & Oil Slinger/Filter Cleaning
Pit bike Front Manual Clutch Adjustment
Pit bike Semi Auto Clutch Adjustment
How to True a Motorcycle wheel
Pit Bike Head Comparison
YX 150/160, ZS 155 Head types
Pit Bike Cylinder sizing
KLX110 & DRZ110 YX/ZS TB Race Head & Cam Info
Pit Bike and Motorcycle CHAIN sizing
Pit Bike Engine Size & 50/70 Engine Size
Engine Info for Kits
Exhaust Pipe Adapters
How to measure for an Air Filter
Pit bike Piston Sizing
Pit Bike Kick Starter Sizes
Honda Z50 Identification Guide
Honda CT70 Identification Guide
CRF50 Honda & Pit Bike Interchangeability of Parts
Pit bike Heads & Cylinders - Round Cam cover or KLX type
Front Sprockets or Countershaft sprockets
Simple Guide to Jetting
How to Adjust Rear Clutch Cable
& Clutch Will Not Disengage
Engine and Carb quick check list
Low compression and Smoking
Getting started with a new Carb
How to adjust Carb floats
CT70 Z50 Copy Skyteam, SSR , Pitster , Piranha Flashback 125cc emission bypass
How to re-install the clutch washers / Plate on a rear clutch motor & Clutch info
Top End, Valve Clearance, and Timing
4 Stroke Ring stack
Big Bore & Clutch Kit
De Comp install info
KLX 110 Manual
Oil Cooler Connections IMPORTANT
.Pit bike Engine Install Info Z50 XR50 CRF50 CT70 Honda & China
Piston Ring end gap
TB Oil Cooler Install Guide
TB Manual Clutch Install CRF50/70 & How to adjust front manual clutches
Engine Tear Down Instructions
Race Head Assembly
High Volume Oil Pump
88 Kit Install
TB Manual Clutch Install KLX (Semi & Full Manual)
Stock O Rings
Honda Z50 Suspension Set Up Info
CRF110 Big Bore Kit Install Guide
Advanced Engine Build Checking Valve to Piston clearance
Engine & Engine Build Terms
Understanding Cam Gear Ratios
How to measure a Bolt or Axle
Oil Cooler info
Pit Bike OEM & After-market Performance Carbs TECH
Cylinder Head Install info TECH
Roller Rocker Head Technology (V2 Heads)
Common 110cc Misconception
General Piston Info
Pit Bikes engines fit Honda Frames NOT Kawasaki KLX110
Cradle Frame info
Cable Spec Chart
High Performance Exhaust Pipes For Pit Bikes
Do You need to Run Race Gas and Fuel Stabilizer
THUMPSTAR and SIKK MX Discontinued Rear Wheels
VIN Number Location
How to measure a Metric Pit Bike Bearing
Shop Manuals for Honda Z50 & Other Minis
Pit Bike Engine OEM Parts
Pitster Pro / ZS 160 HO Engine breakdown
Mikuni VM Manual
Piranha 140cc Engine Diagram (YX140, DTE140)
YX 90cc Engine Diagram
Piranha 150cc Engine Diagram (YX150, DTE150)
YX 125cc Breakdown
OEM Stock Parts sizes for CRF & KLX Pit bikes
How To Install A Manual Clutch In Your XR / CRF 50
C1. One of the biggest performance upgrades you can make to your XR or CRF 50 is to replace the stock semi auto clutch with a fully manual clutch. By adding a manual clutch, you can expect your 50 to launch harder out of corners, and you can also expect to get a faster jump off the starting line. For this ï¿½How Toï¿½ article, we opted to use the proven 3-plate manual clutch kit from Honda Trail Bikes. This kit comes with everything you need except for the clutch lever and perch. With a little time and patience, the Trail Bikes clutch is fairly easy to install and is well worth the effort.
C2. To begin the process, drain the engine oil and remove the foot peg mount. Once the oil has been drained, use an 8mm socket to remove the clutch cover bolts and remove the cover.
C3. Use a Phillips head screwdriver (or in impact driver) to remove the 4 screws from the outer clutch cover.
C4. Use a small flat blade screwdriver and open up the tabs on the lock washer. Use a clutch nut tool and a strap wrench to remove the black retaining nut. Remove the clutch assembly.
C5. Remove the primary drive gear.
C6. Remove the dimpled bushing.
C7. Use snap ring pliers to carefully remove the snap ring. Remove the large driven gear.
C8. Remove the stepped collar.
C9. Use a 10mm socket to remove the 2 bolts securing the stopper plate and stopper arm. Be sure to pay attention to how the stopper plate and stopper arm line up.
C10. Carefully remove the gearshift spindle assembly.
C11. Install the new gearshift spindle assembly. Be sure that the shift shaft seal on the left side of the bike remains in place while inserting the new gearshift spindle assembly.
C12. Install the new large driven gear.
C13. Install the new stepped collar. The tapered portion of the collar should face away from the engine.
C14. Install the new dimpled bushing.
C15. Install the new primary drive gear.
C16. Install the new clutch assembly. Note that the backside of the clutch assembly locks onto the primary gear. Make sure that the clutch assembly is locked into place before proceeding. Install the new lock washer.
C17. Install the new cup washer. Make sure that the tapered end of the washer faces away from the engine.
C18. Install the new retaining nut. Use a strap wrench and a clutch nut tool to tighten the retaining nut to 31 ft-lb. After the retaining nut has been tightened down, use a small flat blade screwdriver to bend the arms of the lock washer into place.
C19. Install the new outer cover.
C20. Install the new bearing into the outer cover.
C21. Install the new oil passage bushing into the bearing.
C22. Install the new spring into the bushing.
C23. Install the new oil passage tube over the spring and into the bushing.
C24. Flip the new clutch cover over and insert the clutch actuator into place.
C25. Install the new clutch cover gasket over the two existing dowel pins to keep it in place.
C26. Install the new clutch cover into place and secure with the new Allen head bolts included in the kit.
C27. Install a new seal over the kick-start lever.
C28. Remove the chrome cover plate and remove the Phillips head bolt. Remove the clutch actuator plate assembly. Install the new oil seal. Make sure that the oil seal is completely seated. Replace the clutch actuator plate assembly.
C29. Loosen the locknut on the clutch adjuster screw. Tighten the screw until there is very little to no play in the clutch actuator plate. Connect the included clutch cable to the clutch arm and route the cable up to the clutch lever. Be sure that there is a small amount of play at the clutch lever. If not, loosen the clutch adjuster locknut and readjust the clutch adjuster screw.
C30. Install the chrome clutch cover and use your shirt to polish it to a mirror like finish. Take a step back and admire your new clutch set up as you are now done. Now get outside and learn how to ride 3rd gear wheelies.