Two Brothers Racing XR50 User Manual

Heavy Duty Clutch Springs for Honda XR50 (Set of 4)

Part # 010-3-04

Warranty

Two Brothers Racing products are intended for closed course competition purposes only, and therefore are sold
“as is” without warranty. Two Brothers Racing specifically disclaims any warranties of merchantability or fitness for
a particular purpose and disclaims all responsibility for consequential and incidental damages or any other losses
arising from the use of these products or parts.

1. Make sure the bike is completely cool before starting the
installation.

2. Drain engine oil. Remove footpeg bar. Remove kickstarter.
Remove rear brake pedal. Remove the right side cover.

3. Remove the ball retainer and spring. Remove the clutch
lifter lever.

Remove the oil through and spring. Remove the clutch
lifter cam plate.

4. Remove the four bolts holding the clutch plate. Under this
plate is the clutch locknut. Peel back the tab(s) on the lock
washer. Remove this nut using either a Honda clutch lock­nut wrench or the Takegawa clutch locknut wrench (Part #
010-9-01-021, $26.98 MSRP). A flywheel holder tool may
help to remove this part.

5. Remove the lock washer B, 14mm lock washer and clutch
asembly.

6. Remove the following items from the clutch assembly:

- Clutch Set Ring

- Clutch Plate B

- Clutch Disc A

- Clutch Disc B

- Clutch Disc A

- Free Springs (set of 4)

- Clutch Plate A

Next remove the clutch center and drive gear outer.

7. Remove the four phillips head screws and washers (photo
A). Please not the once removed the four damper springs
will drop down (photo B). Turn clutch assembly over and
remove drive plate assembly and clutch springs (photo C).

8. Install new heavy duty clutch springs onto drive plate
assembly. Reinstall drive plate assembly/heavy duty clutch
springs into clutch outer assembly.

9. Reinstall the four phillips head screws and washers.
Tighten in a crisscross pattern in 2-3 steps. Torque screws
to 4.3 lbs-ft. (6 Nm)

10. Reinstall damper springs (set of 4). Seat springs into
spring seating hole, then use a flat head screwdriver to
compress the springs and fit them onto the tabs.

IMPORTANT - PLEASE READ CAREFULLY

Installation Instructions

Care & Cleaning / Warranty

XR50 Clutch Springs Instructions.qxd

photo A photo Cphoto B

photo A photo B

We recommend that this performance accessory be installed by a quali­fied motorcycle technician. If you have any doubts as to your ability to
install this performance accessory, please consult with your local motor­cycle dealer. Read all instructions first before starting installation. Make
sure the motorcycle and exhaust system are completely cool before start­ing the installation. Also, make sure the bike is secure on the sidestand or
ideally a rear service stand during installation. Be sure to save all stock
components for possible use later.

11. Reinstall drive gear outer and clutch center.

12. Apply motor oil to disc A & B as
shown in the diagram. Reinstall
the following items from the clutch
assembly:

- Clutch Plate A

- Free Springs (set of 4)

- Clutch Disc A

- Clutch Disc B

- Clutch Disc A

- Clutch Plate B

13. Reinstall the clutch set ring with its chamfered side facing the
clutch plate B.

14. Reinstall clutch assembly onto primary gear. Be sure to fully

seat clutch assembly onto primary gear.

15. IReinstall the 14mm lock washer, lock washer B (with its “OUT­SIDE” mark facing out) and lock nut. Using a flywheel holder
torque lock nut to 31 lbs-ft (42 Nm). If the lock nut groove does
not align with the lock washer tab further tighten the lock nut
until aligned.

16. Reinstall clutch plate and torque screws to 3.6 lbs-ft (5 Nm).

17. Reinstall the oil through and spring. Reinstall the clutch lifter
cam plate.

18. Reinstall the ball retainer and spring. Reinstall the clutch lifter
lever.

19. Reinstall the following

- Right side cover

- Rear brake pedal (adjust free play)

- Kickstarter (see diagram for proper placement)

- Footpeg bar

20. Refill engine oil (.8 quart)

21. Before you run the bike, double check your work.

22. Start engine and let it idle for 2-3 minutes. Stop engine and
inspect for any oil leaks. Double check oil level.

XR50 Clutch Springs Instructions.qxd

Install the clutch disc A with its flat surface facing the clutch disc B.

Install the clutch plate B with its chamfered side facing the clutch
disc A.

20

Side view of kickstarter

Front of bike

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