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Summary of Contents for Rekluse RadiusCX
- Page 1 INSTALLATION & USER’S GUIDE RadiusCX Clutch For KTM/Husqvarna DS Clutches Doc ID: 191-7913A Revision: 082018 ©2017 Rekluse Motor Sports Rekluse Motor Sports, Inc. customerservice@rekluse.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS OVERVIEW ................3 INSTALLATION TIPS ..............3 Tuning Note ................4 TOOLS NEEDED ............... 4 INCLUDED PARTS ..............5 DISASSEMBLE THE CLUTCH ..........7 CLUTCH PACK INSTALLATION ..........10 Notes for Clutch Pack Installation: ........10 Clutch pack overview ............14 PRESSURE PLATE INSTALLATION ........ -
Page 3: Overview
• The OE center clutch hub, pressure plate, clutch cover, and clutch pack are replaced with high-quality billet components. • All OE steel drive plates will be replaced with Rekluse TEC drive plates. • All OE friction disks will be replaced with Rekluse ®... -
Page 4: Tuning Note
Tuning Note : (especially for 2-stroke owners): • Once installed, if you desire your clutch to engage more aggressively, one option is to purchase the heavier Belleville spring from KTM (KTM calls it the “280” spring). • Replacing this spring makes the clutch engagement more aggressive. -
Page 5: Included Parts
INCLUDED PARTS Item Description Qty. Center hub Steel drive plates ® TorqDrive friction disks Lining plate EXP base EXP wedge assembly 60 / 60.1 EXP adjustment springs (colors vary) Quarter turn pins (includes 2 extra) Pg. 5 Doc ID: 191-7913A Doc Rev: 082018... - Page 6 Tab lock washer Adjustable slave cylinder assembly Not shown Torx head screws (T-25 Torx bit included) Not shown Orange Free Play Gain rubber band Visit www.rekluse.com/support a full parts fiche illustration and part numbers. Pg. 6 Doc ID: 191-7913A Doc Rev: 082018...
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Page 7: Disassemble The Clutch
DISASSEMBLE THE CLUTCH 1. Turn the fuel petcock to “OFF” if applicable. 2. Lay the bike on its left side. Catch any fuel that might drain in a suitable container. 3. Use an 8 mm socket to remove the clutch cover. If your bike has an oil plug, loosen the plug before removing the cover. - Page 8 6 pressure plate screws Spring ring Belleville spring Slider ring Pressure plate Throw-out bearing and washer Clutch pack 6 Drive pins Be careful that the drive pins do not fall into the engine while disassembling. Pg. 8 Doc ID: 191-7913A Doc Rev: 082018...
- Page 9 5. Use a hammer and large screwdriver to bend down the tabs of the washer tab, then remove the center clutch nut with an impact wrench or breaker bar, and a 27 mm socket. 6. Remove the OE tab washer. 7.
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Page 10: Clutch Pack Installation
• Some OE basket 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. Installing the pack in the “half slots” will cause performance issues. See the following picture for reference. - Page 11 2. Install the new Rekluse center hub into the clutch basket. Make sure the thrush washer is still in place. Rekluse inner hub Thrust washer 3. Reinstall the new Rekluse tab washer and center clutch nut. 4. Using the 27 mm socket and torque wrench, torque the center clutch nut to 50 ft-lb (68 N-m).
- Page 12 7. Hold a TEC drive plate so that the “shark fin” notches face toward the right. All the drive plates will follow this orientation. Note: Proper orientation of the drive plates is critical for optimal clutch performance. If you install them backwards, the clutch will still function but will lack proper modulation performance.
- Page 13 Note: ALL the steel drive plates must be aligned in the drive pins notches or damage may occur. The plates will not move when installed correctly. 9. On top of the steel drive plate, install a Rekluse fiction disk. 10. Continue alternating the steel drive plates with the friction disks for the entire Rekluse clutch pack.
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Page 14: Clutch Pack Overview
Clutch pack overview Steel drive plate TorqDrive friction disk Alternate steel drive plates with friction disks EXP disk Total clutch pack: 8 steel drive plates and 7 friction disks Pg. 14 Doc ID: 191-7913A Doc Rev: 082018... -
Page 15: Pressure Plate Installation
Add a light film of oil between the lining plate and pressure plate. This will help the plates stick together for ease of installation. Install the supplied lining plate onto the new Rekluse pressure plate by lining up the index tabs into the slots. Pg. 15... - Page 16 Install the pressure plate subassembly by lining up the index tabs on the pressure plate with the slots in the hub. NOTE: When the pressure plate is seated correctly, the threaded standoffs will come through the openings of the pressure plate. Pressure plate with lining plate...
- Page 17 II (4-strokes and 2017 + 2- strokes) or X (pre 2017 2-strokes). In most cases, this is the best starting point for the clutch. Install the Rekluse pressure plate screws. Do not reuse the OE screws, or clutch cover interference will occur! Pg.
- Page 18 Remove the OE cover gasket from the OE clutch cover and install it onto the new Rekluse clutch cover. Install the Rekluse clutch cover, then lightly tightening the cover bolts in a star pattern. Tighten bolts in small increments before torqueing the cover bolts to OE specifications.
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Page 19: Slave Cylinder Installation
SLAVE CYLINDER INSTALLATION Installing the new Rekluse slave cylinder takes several steps. Please read the entire section before beginning the process to ensure you have the right equipment and clutch fluid needed for the replacement. Rekluse recommends wearing gloves and safety glasses for the install. - Page 20 2. Use your thumbs to compress the piston until it bottoms out, then release Pour the recommended clutch fluid into the slave cylinder port. Be sure to use the correct clutch fluid. Check the cap of the clutch master cylinder to determine which clutch fluid to use.
- Page 21 9. Compress the piston until it bottoms out, and top off with fluid. 10. Check that the ball bearing is still in place. Stand the Rekluse slave cylinder in an upright position (so the fluid does not spill) until it is needed in the next step. Pg. 21...
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Page 22: Step 2: Replace Oe Slave Cylinder
Step 2: Replace OE slave cylinder In this step, the OE slave cylinder is replaced with the Rekluse slave cylinder. Work quickly when performing the following steps. This method retains the fluid inside the line, and makes the final bleeding step easier. - Page 23 3. Separate the OE slave cylinder from the clutch fluid line. 4. Remove and discard the 2 OE crush washers. 5. Attach the clutch fluid line to the Rekluse slave cylinder using the OE banjo bleeder bolt and the 2 crush washers from Rekluse.
- Page 24 7. With the clutch fluid line attached to the Rekluse slave cylinder, remove the OE slave cylinder from the engine. Keep the OE bolts for reuse. 8. Mount the Rekluse slave cylinder to the engine using the OE bolts. NOTE: Some models have a piston diaphragm seal. DO NOT reuse them if OE equipped.
- Page 25 If not supplied, use the OE gasket. NOTE: If you need to install the case sealing O-ring seal (OE or Rekluse supplied), make sure it is seated against the slave cylinder flange. 9. Torque the banjo bolt to OE specification.
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Page 26: Bleed The Clutch Line
Optional: If you purchased the Rekluse Slave Guard accessory, install it now using the specific instructions included with the slave guard kit. BLEED THE CLUTCH LINE 1. Attach one end of the supplied bleed tube to the banjo bolt port, then loop the opposite end into a suitable catch bottle. - Page 27 2. On the handlebar, remove the cap and bladder from the clutch master cylinder. Adjust the reservoir so it is level with the ground. 3. Top off the master cylinder with the recommended clutch fluid until it is 75% full. 4.
- Page 28 5. While still holding the clutch lever in, use a wrench to open the bleed port. Air and fluid should flow from the bleed tube. 6. Before releasing the clutch lever, tighten the bleed port when the pressure is released from the bleed tube. 7.
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Page 29: Set The Installed Gap
SET THE INSTALLED GAP It is very important that you understand how to set the installed gap in your new clutch, and be able to verify the installed gap by checking Free Play Gain. Setup, break-in, and rechecking the installed gap is CRUCIAL. -
Page 30: Step 1: Find The Starting Point
Step 1: Find the starting point With the bike standing up, locate the adjuster screw in the center of the adjustable slave cylinder. With the O-ring showing, use a 4 mm hex key to turn the adjuster screw clockwise until it stops under light pressure. -
Page 31: Step 2: Learn How To Check Free Play Gain
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 Pg. -
Page 32: 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 33 A Rekluse auto-clutch can make your motorcycle appear to be in neutral when in gear, even when the engine is running and clutch lever released. Motorcycles equipped with a Rekluse auto-clutch can move suddenly and unexpectedly and cause riders to lose control.
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Page 34: The Hand Method
Note: It is very important the motor returns to idle before revving the engine again or Free Play Gain will not be correct. When the bike returns to idle, rest your hand across the clutch lever. Rev the engine again to 5,000-7,000 RPM so you can observe the movement while feeling for Free Play Gain with your hand. -
Page 35: Step 3: Break-In The New Clutch
Step 3: 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 36 4. With the bike idling in first gear, slowly apply throttle to begin moving. 10 roll-on starts 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. NOTE: If the engine wants to stall or the creep is excessive, the idle may be too high or the installed gap may...
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Page 37: Step 4: Adjust The Installed Gap And Recheck Free Play Gain
7. Place the bike in NEUTRAL and recheck Free Play Gain. 8. Continue to step 4 to adjust the installed gap until the Free Play Gain of the clutch lever is 1/8”-1/4” (3 mm-6 mm). Recheck Free Play Gain and adjust the installed gap NOTE: Your clutch pack will expand with heat, so final adjustment to Free... - Page 38 Use a 4 mm hex key to turn the adjuster screw clockwise 1 tick mark from the last setting, then recheck Free Play Gain. Tick marks are located on the slave cylinder, and an etch mark is on the screw. If you need to re-position the hex key, you can use these marks for reference.
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Page 39: Free Play Gain Adjustments
FREE PLAY GAIN ADJUSTMENTS Make each adjustment in small increments - one tick mark at a time. After each adjustment, recheck Free Play Gain until you achieve the optimal 1/8”-1/4” (3 mm-6 mm) of clutch lever movement. Symptom Reason Solution •... -
Page 40: Maintenance
MAINTENANCE To keep your clutch performing at its best, perform regular maintenance on your bike and clutch. • Keep up with regular oil changes as per the bike manufacturer’s recommendations. Clutch performance and longevity depend on oil quality. • Inspect all of your clutch parts for signs of wear or excessive heat, and replace components as necessary. -
Page 41: Disk Inspection Examples
These are best viewed in color by viewing this install document from www.rekluse.com/support. Drive Plates – If the clutch pack is getting high amounts of heat, purple, blue, or black color can be seen on the drive plate teeth. -
Page 42: Troubleshooting
Friction Disks – Due to the dark color of the friction material, the friction disks will appear almost black as soon as they are put in oil. During inspection, look for glazing of the friction material. Glazing will appear shiny and feel like glass, even after oil is cleaned from the friction disk. -
Page 43: Clutch Noise
For bike models that have clutch squeal or chatter here are some recommendations to reduce or eliminate it: • Change the oil: Rekluse recommends that you have fresh, clean JASO-MA or JASO-MA2 rated oil for best clutch performance. Dirty or old oil can make the clutch more likely to squeal or chatter. -
Page 44: Configuration Chart
Configuration chart ENGAGEMENT SETTING 6 Silver 3 Silver & 3 Steel Medium 3 Silver & 3 Red 6 Silver Medium High 3 Red & 3 Silver 6 Red 6 Red High Changing the springs 1. Using a flat-blade screwdriver, push the ¼ turn pin in far enough to clear the opposite side of the EXP to unlock the pin. - Page 45 7. If you need to disassemble the EXP disk, you can watch the video on our website under Tech Tips at www.rekluse.com/support/videos/atv-mc-support-videos. NOTE: To maintain even pressure, when using two different color spring sets, install one set of 3 on one side of the EXP and the remaining set of 3 on the other side.
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Page 46: Bump-Starting
If you disassemble the EXP, the Teflon pads may fall out or be stuck to the ramp surfaces of the EXP bases. Take care to ensure all pads are correctly placed into wedge pockets using gentle pressure to avoid damage to the pad surfaces before reassembling the EXP. -
Page 47: Need Additional Help
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. Hours: Monday thru Friday: 8:00 a.m. - 5:00 p.m.
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