EVOLUTION POWER Maverick X3 Tapp Primary Clutch Kit Instruction Manual

EVOLUTION POWER Maverick X3 Tapp Primary Clutch Kit

Product Information

The TAPP x Evolution Clutch is a primary clutch system designed for installation on various vehicles. It includes several parts to enhance clutch performance and customization options:

• (1) TAPP Uncalibrated Clutch
• (4) Sets of Rollers
• (4) Sets of Ramps
• (1) Primary Clutch Spring
• (1) Primary Clutch Cover

The clutch system requires specific tools for installation and adjustment:

• Allen Sockets
• Ratchet Torque Wrench
• Blue Loctite
• Allen Wrenches
• Clutch Compressor Tool

Product Usage Instructions

Installing the TAPP Clutch:

1. Bolt the TAPP clutch onto the engine crankshaft using a new primary bolt. Do not use the OEM clutch bolt.
2. Use the X3 XR Series Primary Clutch Bolt specifically designed for the TAPP clutch (SKU: XXX) from EVP.

Adjusting the TAPP Clutch:

Adjusting Ramp Angle:

The TAPP primary clutch has two sides (A and B) with different ramp angles. Follow the steps below to adjust the ramp angle:

1. Refer to the diagram for the numbered positions of the adjustable components.
2. Choose the desired ramp angle by rotating the ramps to the corresponding positions.

Adjusting Ramp Profile:

The TAPP primary clutch allows adjustment of the ramp profile to achieve different engagement levels. Follow the steps below to adjust the ramp profile:

1. Refer to the diagram for the numbered positions of the adjustable components.
2. Select the desired ramp profile by aligning the convex or the concave side of the ramps.
3. Engagement level varies based on the selected ramp profile and RPM range.

Adjusting Roller Size:

The TAPP primary clutch offers different roller sizes to fine-tune clutch performance. Follow the steps below to adjust the roller size:

1. Select the desired roller size by choosing rollers with different OD measurements and weights.
2. The available roller sizes and their corresponding measurements and weights are as follows:

Adjusting Weight on the Roller:

The TAPP clutch includes a roller weight kit for further customization. Follow the steps below to adjust the weight on the roller:

1. Refer to the provided hardware and dimension chart for the weight options.
2. Use the appropriate socket head screw and washer combination to achieve the desired weight.

Note: Using Socket Head Screw 1.50 does not allow for added weight.

TAPP Primary Spring(s):

The TAPP clutch system offers various primary springs with different ratings and engagement levels. Choose the appropriate spring based on your vehicle setup:

Installing the Primary TAPP Clutch:

For proper installation of the TAPP clutch, follow the valve lapping technique between the clutch and the engine crankshaft.
This should be done every time the clutch is removed to ensure a secure fit. We recommend using PermatexTM fine grit for this process.

TAPP x Evolution Clutching Instructions SKU(s):

INCLUDED PARTS

(1) TAPP Uncalibrated Clutch

(4) Set of Rollers
(4) Set of Ramps
(1) Primary Clutch Spring
(1) Primary Clutch Cover

REQUIRED TOOLS

Allen Sockets, Rachet

Torque Wrench
Blue Loctite
Allen Wrenches
Clutch Compressor Tool

Installing the TAPP Clutch:

• The TAPP clutch will bolt on just like the OEM primary or other aftermarket primary clutches. However, you will need a new primary bolt. DO NOT use the OEM clutch bolt as you can possibly destroy the TAPP clutch sheave or the crank to your engine. EVP designed and built a primary clutch bolt specifically for the TAPP clutch that outperforms anything else on the market. X3 XR Series Primary Clutch Bolt, TAPP (SKU:XXX)

Adjusting the TAPP Clutch:

• There are (4) main adjustable components on the TAPP primary clutch: Ramp Profile, Ramp Angle, Roller Size, Adjustable Weights. Always use Blue Loctite when adjusting the weights.

Adjusting Ramp Angle:

• The ramp angle in your TAPP Clutch is adjustable from the outside via the use of the Quick Shift Bolts. As with other clicker style clutches the higher the number, the higher the RPM. This will mainly affect the full shift speed but also affects the engagement and low speed slightly. On the TAPP clutch each ramp has its own quick clicker adjustments. Each clicker has (6) adjustments. Each click will add or subtract 25rpm but they need to be done opposite pairs actually adding/subtracting 50rpm.
• IMPORTANT – Always adjust the ramp angle in pairs across from each other, if you do not the clutch will be out of balance.

Adjusting Ramp Profile:

• Your TAPP clutch comes with a set of (4) pre-chosen ramps that have been tested in many scenarios and have been deemed to be the most generic in most situations. Each ramp has an “A” profile side and a “B” profile side. The “A” side will always have lower engagement, “B” side will have higher engagement. Changing the profile of the ramp will have many effects on the shift profile including engagement rpm and back shift. This should only be done by an experienced tuner.
• IMPORTANT – Always adjust the ramp profile in pairs across from each other, if you do not the clutch will be out of balance.
• Flipping 2 ramps from the “A” side to the “B” side you will increase your engagement by roughly 600- 800rpm.
• Flipping all 4 ramps from the “A” side to the “B” side you will increase your engagement roughly 1200-1600rpm.

Medium/High
1335 Concave| A Side 1700+ rpm**

B Side 2400+ rpm

| Low/Medium
1336 Concave| A Side 1700+ rpm B Side 4500+ rpm| Low/High

Adjusting Roller Size

There are 3 sizes of rollers available: standard, 1mm oversize, and 2mm oversize. Bigger rollers make the low-end “quicker RPMs” but shift out quicker and lower the full shift RPM. Smaller rollers make the engine slower shift and raise the full shift RPM. This has to do with the angle of the arms combined with the weight difference of the rollers. The roller assembly consists of a roller, axle, and two washers.
IMPORTANT – As with the ramp angle roller size must be done in pairs across from each other, failure to do so will result in an imbalance of the clutch and possibly failure.

Roller Assembly : Roller, axle, (2) washers located on the outside of the roller.

Adjusting Weight Overview

• The weight in the arms can be adjusted in two ways: set screws in the arms, and washers on the roller thru bolt. Your clutch was shipped with a basic tuning kit. As with all other clutches add weight to lower RPM, and remove weight to raise RPM.
• Set screws in the arms affect the low-speed shift points more than the high-speed and will reduce the max RPM.
• The weight on the roller axle bolt acts like the tip weight in a conventional clutch affecting the high speed more than any other part of the curve. Adjust this as needed for your application.

IMPORTANT – As with all other adjustments, do this evenly and only in pairs across from each other, failure to do so will result in an imbalance of the clutch and possible failure.

Adjusting Weight on the Arms:

• Allen screws must be added in pairs opposite to one another. Allen screws are .500” weighing 2.7 grams. Adding two Allen screws will add 5.2 grams. Added all eight Allen screws will add 20.8 grams.

Adjusting Weight on the Roller:

The TAPP clutch includes a roller weight kit with the following parts.

• Using Socket Head Screw 1.50” doesn’t allow for added weight.
• Using Socket Head Screw 1.75” allows for a max of 4 washers adding 5.8 grams.
• Using Socket Head Screw 2.00” allows for a max of 8 washers adding 10.3 grams.
• Using Socket Head Screw 2.00” allows for a max of 2 race weights adding 16.7 grams.

TAPP Primary Spring(s)

Spring Color        Spring Rating Engagement Rating 2.8”/1.50”

Blue| 100/190| 3200-3800 rpm with less than 400hp setup
__

Black

| __

140/210

| 3600-4200 rpm with less than 400hp setup 3800-4500 rpm with more than 400hp setup
Red| 160/270| 4200-5000 rpm with more than 400hp setup
Orange| 40/210| 1800-2800 rpm with less than 400hp setup
Yellow| 40/300| 1800-2800 rpm with less than 200hp setup

Installing the Primary TAPP Clutch

• We have found the best way to install the TAPP clutch is by the “valve lapping” technique between the clutch to the engine crankshaft.
• This should be done every time you remove the clutch from the engine crankshaft to ensure there is a perfect mate between the clutch tapper and crankshaft taper not allowing the clutch to spin on the crank.
• We recommend Permatex™ fine grit.
• Step 1: Put nitrile gloves on, and lightly apply the Valve Grinding Compound onto the crankshaft taper and clutch taper.
• Step 2: Slide the clutch onto the crankshaft, and spin the clutch in one direction, 25 cycles with your hands. Pull the clutch off and look for a uniform grey section all the way around the crank.
• When a new crank is installed you must do this three times, or until uniform all around the crank.
• Step 3: Once complete, brake clean all the valve lapping compound off the crankshaft and clutch.
• If you don’t remove all the compound, you will ruin the crankshaft and clutch taper.

Installing the Primary Clutch Bolt

• If you are using the OEM bolt, you will need to torque the primary bolt down to 89 ft/lbs and drive the car up to 4000 rpms, re-torque to 89 ft/lbs. Do this a total of (3) times to ensure the primary bolt is torqued completely or it can come off.
• If you are using our recommended XR Series Clutch Bolt, you will need to torque the primary bolt down to 115 ft/lbs and drive the car up to 4000 rpms, re-torque to 115 ft/lbs. Do this a total of (3) times to ensure the primary bolt is torqued completely or it can come off.

UTV CALIBRATION KIT FITMENTS

• Thank you for choosing Evolution Powersports products. If you require further assistance, please call our Tech Support @ 715-247-3862
• Note: This product is exempt from the emission standards and related requirements of 40 C.F.R. § 1051 as provided by 40 C.F.R. § 1051.620, and California law [e.g., vehicle code§§ 27156 and 38391].
• This product is sold only for use in connection with EPA-certified, purpose-built, nonroad vehicles used solely for closed course, nonroad competition/racing, and not used for any recreational purpose or on public highways or right of ways maintained by and open to the public. This product is sold only in connection with machines that do not fall under state and/or federal noise or emission standards/regulations. Purchasers who/purchase this product represent and warrant that the product is purchased only in connection with EPA-certified, emission-regulations-exempt, and noise-regulations-exempt competition/racing vehicles as interpreted under applicable state and/or federal law. Questions: Call Evolution Powersports at 715-247-3862.

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