Rekluse RadiusX Clutch Installation & User Manual
For pull-style, cable actuated street bikes
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Summary of Contents for Rekluse RadiusX Clutch
- Page 1 INSTALLATION & USER’S GUIDE RadiusX Clutch for Pull-Style, Cable Actuated Street Bikes Doc ID: 191-6313A Revision: 041819 ©2019 Rekluse Motor Sports Rekluse Motor Sports, Inc. customerservice @rekluse.com...
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Page 2: Table Of Contents
The Hand Method ............19 ADJUST THE INSTALLED GAP ......... 19 BREAK-IN THE NEW CLUTCH .......... 21 CLUTCH LEVER OPTIMIZATION ........23 Optimization with Rekluse Adjustable Reach Lever ..23 MAINTENANCE ..............24 Clutch wear ..............24 Clutch parts ..............24 Basket ................ -
Page 3: Overview
• This kit will replace all the OE friction disks and drive plates with a Rekluse thin friction EXP clutch pack. • The OE pressure plate springs are replaced with high quality Rekluse springs. - Page 4 Doc ID: 191-6313A Pg. 4 Doc Rev: 041819...
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Page 5: Tools Needed
DISASSEMBLE THE CLUTCH 1. Soak the Rekluse friction disks in new oil for at least 5 minutes. Make sure the friction disks are coated on both sides. Pg. 5 Doc ID: 191-6313A... - Page 6 2. If applicable, turn the fuel petcock to “OFF.” 3. Drain the oil or lean the bike on its side. 4. Before removing the clutch cover, be sure to note the positon of the clutch actuator arm as shown below. This is critical for adjustment.
- Page 7 7. Remove the OE pressure plate bolts, springs, pressure plate, and throw-out. Pressure plate OE Pressure plate springs and bolts Throw-out 8. Remove the clutch pack. Pg. 7 Doc ID: 191-6313A Doc Rev: 041819...
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Page 8: Clutch Pack Installation
Note: Some models have a clutch boss spring located in the bottom of the OE friction pack. This consists of a spring, seat and narrow friction. If your bike is equipped with these parts, remove them and set the spring aside. Only some bikes will reuse the spring. - Page 9 • Some OE baskets have “half slots” at the top of the basket tangs. Rekluse products require the entire clutch pack be installed into the MAIN (deeper) basket slots. Do not use the “half slots.” See the following picture for reference.
- Page 10 • Inspect your OE center hub and pressure plate flanges for excess wear. If wear is visible use a drop gauge to verify that the wear across the flange does not exceed .005” (.12mm). Doc ID: 191-6313A Pg. 10 Doc Rev: 041819...
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Page 11: Install Clutch Pack
Install Clutch Pack 1. Install all of the Rekluse basket sleeves into the basket slots. Make sure the bottom of the sleeve is facing down, and the sleeve tabs sit against the inside of the basket. See following pictures for reference. - Page 12 3. Reinstall the throw-out and pressure plate, then install the Rekluse pressure plate springs and bolts. If your kit includes Rekluse screw sleeves or spring bolts, install them in place of the OE components. If not, resuse the OE components.
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Page 13: Clutch Cover Installation
CLUTCH COVER INSTALLATION Before securing the clutch cover in place or reattaching the clutch cable bracket to the engine, follow the next steps to achieve the correct actuator arm orientation to ensure adequate cable travel during use. Note: The clutch actuation mechanism is a rack and pinion system. - Page 14 1. Align the teeth on the throw-out with the teeth on the actuator shaft in the clutch cover. Replace the clutch cover carefully, ensuring the throw out rod connects with the actuator shaft. Note: Yamaha R3 models only: An additional adjustment is required for the actuator arm on this bike.
- Page 15 2. The actuator arm should be aligned so that when the cable is reattached the arm is in the position that was noted before installation. Note: Ensure it matches the position that was noted on your bike specifically as it may differ on other bikes. a.
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Page 16: Set The Installed Gap
You can also view the video entitled “How to Check Free Play Gain” on our website at www.rekluse.com/support/videos. Optimal Free Play Gain yields 1/8”-1/4” (3 mm-6 mm) of clutch lever movement, measured at the ball end of the Doc ID: 191-6313A Pg. -
Page 17: Two Ways To Check For Free Play Gain
Two Ways to Check for Free Play Gain There are two ways to check for Free Play Gain. One way uses the rubber band Rekluse includes in the clutch kit, and one uses your hand. You can use either method to check for Free Play Gain. - Page 18 b) Stretch the included rubber band between your thumbs, and then place the top end of the rubber band on the outer end of the left handlebar grip. c) While holding the top end of the rubber band against the handlebar, stretch the band downward, and then loop it through itself.
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Page 19: The Hand Method
The Hand Method a) Before you begin, place the bike in NEUTRAL, start the engine and let it warm up for 2-3 minutes to idle down and warm up the engine oil. b) With the bike at idle, use one finger to apply pressure at the end of the clutch lever. - Page 20 Notes: If you are unable to obtain the correct Free Play Gain or you are nearly out of cable adjustment after performing the adjustment, your cable may be worn or stretched from wear or use. If this is the case, purchasing a new cable should provide the necessary performance.
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Page 21: Break-In The New Clutch
BREAK-IN THE NEW CLUTCH Once you install your new clutch, it is important to break it in. A series of roll-on starts are used to break in the clutch. Follow these procedures for breaking in your clutch and any time new friction disks, EXP bases, Teflon pads, or wedges are installed. - Page 22 5. Without using the clutch lever, accelerate moderately to approximately 5,000 RPM to fully lock up the clutch and come to a complete stop. Repeat 10 times. 10 roll-on starts Note: If the engine wants to stall or the creep is excessive, the idle may be too high or the installed gap may be too small.
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Page 23: Clutch Lever Optimization
CLUTCH LEVER OPTIMIZATION If your bike model is not equipped with a perch adjuster bolt, you may purchase, as an option, a Rekluse Adjustable Reach Lever. Adjust the lever: • Set the clutch lever to the desired reach point while maintaining clutch lever slack. -
Page 24: Maintenance
Clutch wear Rekluse clutches are built using high quality materials but do wear based on the rider’s use, type of terrain, and natural wear and tear. To keep your clutch performing at its best, perform regular maintenance on your bike and clutch based on your riding style. -
Page 25: Basket
• Inspect and replace basket sleeves if they appear to be notched from friction disks. Rekluse recommends replacing them every 25 hours for abusive riding/racing, every 50 hours for moderate riding, or every time friction disks are replaced. -
Page 26: Need Additional Help
Not all friction disks look the same and may look different than pictured. Normal Glazed Friction Friction NEED ADDITIONAL HELP? Website www.rekluse.com/support Doc ID: 191-6313A Pg. 26 Doc Rev: 041819... - Page 27 Frequently asked questions www.rekluse.com/faq Support Videos www.rekluse.com/support/videos Phone (208) 426-0659 Technical Support Contact Technical Support for questions related to product installation, tuning, and performance. Hours: Monday thru Friday: 8:00 a.m. - 5:00 p.m. Mountain Time zone Email: tech@rekluse.com Customer Service Contact Customer Service for additional product information, orders, and returns.
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