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Related Manuals for Rekluse RADIUSX BMW F650
Summary of Contents for Rekluse RADIUSX BMW F650
- Page 1 INSTALLATION GUIDE For BMW F650, F700, F800 Parallel Twins Doc ID: 191-6305A Revision: 101818 ©2015 Rekluse Motor Sports Rekluse Motor Sports, Inc. customerservice@rekluse.com...
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Page 2: Table Of Contents
NEED ADDITIONAL HELP? ............30 OVERVIEW This kit replaces the OE (Original Equipment) or “stock” clutch pack with Rekluse high quality billet components designed specifically for your bike model. • This kit will replace all the OE frictions and drive plates with a Rekluse TorqDrive ®... -
Page 3: Installation Tips
• This kit includes extra EXP springs, which can be used to tune for your desired engagement. See the EXP tuning options section in this document for specific tuning information. INSTALLATION TIPS • Read the separate included Safety Information document before operating the vehicle with the product installed. -
Page 4: Included Parts
® Basket sleeves Not shown Velcro straps Not shown Orange Free Play Gain rubber band Not shown Clutch lever warning label Visit rekluse.com/support for a full parts fiche illustration and part numbers. Pg. 4 Doc ID: 191-6305A Doc Rev: 101818... -
Page 5: Use Of Other Aftermarket Products
• Bikes with heavily modified engines for increased horsepower may require stiffer pressure plate springs which can be purchased separately from Rekluse. • If your bike is equipped with an aftermarket clutch cable, you may find that the adjustment range in your cable is different from described in this manual. -
Page 6: Disassemble Clutch
DISASSEMBLE CLUTCH 1. Soak the EXP disk and TorqDrive friction disks in ® primary/transmission oil for 5 minutes. Make sure the EXP and friction disks are coated on both sides. 2. Lay the bike on its right side. Catch any fuel that might drain in a suitable container. - Page 7 6. Remove the clutch cable from the clutch cover. 7. Remove the oil fill cap. 8. Remove the clutch cover bolts and clutch cover, taking care not to damage the cover gasket. Replace this gasket if it is torn or damaged. Note: The washer on the shifter shaft may stick to the...
- Page 8 9. Remove the OE pressure plate bolts and springs, throw-out, and pressure plate. 10. Remove the entire OE clutch pack. Pg. 8 Doc ID: 191-6305A Doc Rev: 101818...
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Page 9: Install The Clutch Pack
• 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... -
Page 10: Clutch Pack
-Thick friction disk -Thick steel drive plate 3. Install ALL the Rekluse basket sleeves into the OE basket slots with the tabbed side facing toward the inside of the clutch basket. Push the down until they contact the tabs of the first thick friction disk. - Page 11 Note: Use dental picks can help control the basket sleeves when installing the clutch pack. 5. Install the Rekluse EXP disk, then install the last thick drive plate. Remember to install the EXP and drive plate into the main basket slots with the clutch pack.
- Page 12 6. Reinstall the OE throw-out and pressure plate, followed by the pressure plate springs and bolts. Pressure plate Springs and bolts Throw-out 7. Torque the pressure plate bolts in a star pattern to OE specifications. 8. Install a new clutch cover gasket followed by the clutch cover. Make sure that the throw-out is aligned correctly with the actuator mechanism in the cover.
- Page 13 10. Reinstall the left side kickstand bracket and the shift lever. Use Loctite 243 or equivalent thread-locking compound, then torque to OE specifications. 11. Reinstall the clutch cable to the clutch cover. Thread the jam nut onto the adjuster, but do not tighten it. It will be tightened after you set the Free Play Gain.
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Page 14: Set The Installed Gap
SET THE INSTALLED GAP The installed gap is the separation in the clutch pack created by adjusting the tension in the clutch cable. This gap is what allows the clutch to spin freely until the desired RPM is reached for engagement. -
Page 15: Check Free Play Gain
You can also view the video entitled “How to Check Free Play Gain” on our website at https://rekluse.com/support/videos. Checking Free Play Gain allows you to externally monitor the installed gap so you can know when to make an adjustment if the installed gap is too large or too small. -
Page 16: Two Ways To Check For Free Play Gain
Two Ways to Check for Free Play Gain The following steps explain 2 ways to check 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 17: The Rubber Band Method
Rekluse recommends that you begin with the rubber band method first to check for Free Play Gain and then learn the hand method. The rubber band will help you learn how to recognize Free Play Gain until you are comfortable with the hand method. - Page 18 b) Stretch the included rubber band between your thumbs, 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, then loop it through itself.
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Page 19: The Hand Method
The Hand Method Use the hand method to check Free Play Gain before the start of every ride for optimum performance and longevity of your new clutch. 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. -
Page 20: Adjust The Installed Gap
ADJUST THE INSTALLED GAP After checking for Free Play Gain, you may need to adjust the installed gap. If Free Play Gain is optimal, continue to “BREAK IN THE NEW CLUTCH.” If Free Play Gain is not optimal, the installed gap needs to be adjusted. The installed gap should be fine-tuned in small increments and then recheck Free Play Gain. -
Page 21: Clutch Pack Adjustment
• Solution: Measure your friction disks as per the spec in the maintenance section. If they are within spec, replace the thin Rekluse drive plate below the EXP disk with one thick OE drive plate. If they are out of spec, replace as necessary. - Page 22 Symptom: Running out of adjustment travel on the jam nut (lower) side of the cable adjuster. • Cause: Possible stretched (worn out) cable, or possible incorrect clutch pack configuration. • Consequences: Possibly having too much Free Play Gain and no more room for adjustment; you may have to move the jam nut to the adjustment (upper) side as well if there are not enough threads left for the jam nut on the cable adjuster below the case.
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Page 23: 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 24: Exp Tuning Options
You can tune the engagement RPM of the EXP disk by changing the spring configuration. The EXP disk comes set with the recommended “Medium” setting from Rekluse. Pg. 24 Doc ID: 191-6305A... -
Page 25: Changing The Springs
See the following chart for settings. Use the following steps to change the springs. It is NOT necessary to disassemble the EXP halves to change springs! ENGAGEMENT SPRING CONFIGURATION SETTING 6 Red springs Medium 3 Red & 3 Blue springs High 6 Blue springs Changing the springs... - Page 26 5. Push the turn pin in far enough to clear the base, then turn 90° and release the pin. The pin should sit almost flush with the EXP base. 6. Flip the EXP friction disk over, and repeat on the other side depending on engagement preference.
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Page 27: 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 28: 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 29: Lever Safety Straps
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 30: 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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