TKM BT82 - User Manual

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TKM BT82 V CLUTCH SERVICE & FITTING GUIDE V2
V CLUTCH
All new model Clutched & TAG engines are fitted with a V Clutch and the only available chain sprockets that can be
used are the standard fitment 10 Tooth & the optional 11Tooth.
The V clutch is designed to permit easy starting with a battery operated hand-held remote starter or with the TAG
(touch & go) on-board starter system. When the engine starts, the clutch will be in neutral until the engine reaches
approximately 3400rpm. At about 3500rpm the V clutch will start to engage, and the kart will start to move. Since the
V clutches engages at a low rpm, driving technique will be the same as a direct drive vehicle.
Due to the extreme demands of racing, it is important to properly maintain your V clutch in order to obtain maximum
performance and reduce risk of clutch breakage or clutch slip.
V CLUTCH REMOVAL
Remove the crank starter nut P/N: BTTNUTM10. On the older model clutch drum with through lightening holes, you
can use the V clutch Spanner holding tool so this nut can be undone. On the newer model clutch drum with no
through lightening holes you must use an impact gun to undo and do up this nut set on a low pressure.
Warning: Do not hold the ignition rotor side crank nut or use a piston stop when attempting to undo the crank
starter & clutch hub nuts as this will cause crankshaft to be misaligned & possible engine damage.
Warning: Do not use anything wedged in starter ring gear teeth and crankcase when attempting to undo the
crank starter & clutch hub nuts as this will cause stress and possible starter ring gear damage/failure.
V Clutch Holding Spanner Old Model Drum New Model Drum
Remove the external thrust washer, sprocket & drum assembly, roller bearing and internal thrust washer.
Remove the large V clutch hub nut on the crankshaft with the V clutch holding spanner pictured above & the special
machined long socket pictured below. You can use an impact gun if required. Then remove the large, coned safety
washer.
Special Long Socket for Hub Nut V Clutch Extractor
Remove the V clutch from crankshaft by only using the special designed V clutch extractor tool pictured above.
Finally remove the Woodruff key from the crankshaft.

Summary

V Clutch Removal

V Clutch Description

Explains the V clutch, its engagement, and importance of maintenance for performance.

V Clutch Removal Procedure

Details steps for removing the V clutch using specific tools and techniques.

Clutch Removal Safety Warnings

Crucial warnings against misaligning crankshaft or damaging starter ring gear.

V Clutch Installation

Installation Steps

Guides on inserting Woodruff key, drive hub, washers, and securing nuts correctly.

Torque Settings and Clearance

Specifies torque values for hub nut and starter nut, and end float clearance.

Installation Safety Precautions

Emphasizes avoiding crankshaft misalignment and starter gear damage during installation.

V Clutch Maintenance and Component Service

Roller Bearing and Lubrication

Ensures roller bearing lubrication with grease and warns against excess or copper grease.

Sprocket and Drum Assembly

Recommends chain lubrication, replacing worn sprockets, and correct bolt tightening.

V Clutch Shoes and Springs

Details replacement of worn shoes, springs, and importance of correct fitting.

Clutch Assembly

Instructions for cleaning parts and assembling clutch shoes and springs correctly.

Starter Ring Gear Inspection

Advises inspecting starter ring gear for damage and replacing if necessary.

TKM BT82 Specifications

General

Engine Type	Single cylinder, 4-stroke, air-cooled
Displacement	82cc
Max Torque	4.5 Nm @ 5500 rpm
Cooling System	Air-cooled
Ignition System	CDI
Fuel System	Carburetor
Fuel Type	Gasoline