Rekluse RadiusX Clutch Installation & User Manual
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Summary of Contents for Rekluse RadiusX Clutch
- Page 1 INSTALLATION & USER’S GUIDE RadiusX Clutch for Cable Actuated Bikes and ATVs Doc ID: 191-6300A Revision: 040919 ©2018 Rekluse Motor Sports Rekluse Motor Sports, Inc. customerservice @rekluse.com...
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Page 2: Table Of Contents
ADJUST THE INSTALLED GAP ......... 16 BREAK-IN THE NEW CLUTCH .......... 18 CLUTCH LEVER OPTIMIZATION ........20 Optimization with OE Perch Adjuster ....... 20 Optimization with Rekluse Adjustable Reach Lever ..21 MAINTENANCE ..............21 Clutch wear ..............21 Clutch parts ..............22 Basket ................ -
Page 3: Installation Tips
· 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. INSTALLATION TIPS Read the separate included Safety Information document ·... -
Page 4: 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. Doc ID: 191-6300A Pg. - Page 5 2. If applicable, turn the fuel petcock to “OFF.” 3. For bikes, lay the bike on its left side. Catch any fluids that might drain into a suitable container. For ATVs, drain the oil into a suitable container before disassembly. 4.
- Page 6 Note: Throw-out washers can stick to the back of the pressure plate. Be sure to reinstall any throw-out washers back onto the throw-out. 6. Remove the clutch pack. 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.
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Page 7: Clutch Pack Installation
This mark is used for processing and can be ignored. · 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 8 Note: If the basket is notched or worn, Rekluse recommends replacing it with a Rekluse Billet Clutch Basket (available for most models). · Inspect your OE center hub and pressure plate flanges for excess wear.
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Page 9: 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 10 4. If your kit includes a Rekluse throw-out spacing washer (see setup sheet ), install it on at the back of this manual top of your OEM throw-out. Suzuki RM-Z450 Models: The needle bearing only has the bearings on one side. Make sure that the bearing side is facing the throw-out and the flat side is facing the pressure plate.
- Page 11 OE Bolts Note: DRZ 400, KLX 400, KX 500 bike models: If your kit includes Rekluse screw sleeves or spring bolts, install them in place of the OE components. DRZ 400 and KLX 400 models will utilize the supplied Rekluse screw sleeves and OE bolts, and KX 500 models will utilize supplied Rekluse screw sleeves and Rekluse bolts.
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Page 12: Set The Installed Gap
Note: If the clutch kit includes 2 different colors of springs, be sure to alternate the springs. This will ensure even pressure on the clutch. 6. Torque the pressure plate bolts in small increments in a star pattern to OE specifications. 7. -
Page 13: Learn How To Check 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 14 and/or property damage, always sit on the motorcycle or ATV to start it. a) Before you begin, place the bike/ ATV in NEUTRAL, start the engine and let it warm up for 2-3 minutes to idle down and warm the engine oil. b) Stretch the included rubber band between your thumbs, and then place the top end of...
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Page 15: The Hand Method
When the bike/ATV 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. The Hand Method a) Before you begin, place the bike/ATV in NEUTRAL, start the engine and let it warm up for 2-3 minutes to idle down and warm up the engine oil. -
Page 16: 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 17 Loosen the cable: · Clutch lever only Reduce the length of moves slightly or the cable housing does not move at (collapse the all (too little Free adjusters) until the Installed gap Play Gain) correct amount of is too large Free Play Gain is ·...
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Page 18: 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 19 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 20: 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. Optimization with OE Perch Adjuster Kits for Honda CRF 450 and CRF 250 include a new perch adjuster bolt. -
Page 21: Optimization With Rekluse Adjustable Reach Lever
ATV and clutch. 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/ATV and clutch based on your riding style. -
Page 22: Clutch Parts
· 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 23: Disk Inspection Examples
When inspecting the clutch pack, the following pictures can be used as a reference. These are best viewed in color by viewing this install document at 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 24: Need Additional Help
NEED ADDITIONAL HELP? Website www.rekluse.com/support 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... - Page 25 CLUTCH SETUP SHEET Clutch pack configuration Model CRF450R Qty of friction disks Qty of drive plates 4 - 0.040 in (1 mm) 4 - 0.048 in (1.2 mm) EXP disk Assemble the clutch pack 1. Place the EXP disk into the clutch basket. 2.
- Page 26 Alternate 3 - .040” (1mm) drive plate and 3 friction disks Friction disk .040” (1mm) drive plate Alternate 3 - .048” (1.2mm) drive plates and 3 friction Friction disks disk .048” (1.2mm) drive plate Disk Pg. 2 Doc ID: 198-6301010 Doc Rev: 071117...
- Page 27 This model requires a clutch cover spacing gasket to achieve enough clearance between the clutch cover and the basket sleeves. Use the Rekluse spacing gasket in place of the OE gasket. Lightly tighten the cover bolts in a star pattern. Torque the bolts in small increments before tightening all the bolts to OE specifications.
- Page 28 To prevent free-wheeling and maximize engine braking, set the idle so there is a slight amount of drag while the bike is idling in gear and warmed up. The idle should not be so high that the bike moves forward while in gear with the throttle closed.
- Page 29 on one side of the EXP, then flip the EXP over and install the remaining set of 3 on the other side. Maintenance A few preventive steps can help keep your new clutch performing at its best. Check your Free Play Gain before every ride, and adjust if necessary.
- Page 30 Nominal clutch pack height (Measure steel drive plates, friction disks, and EXP together) = 1.350” (34.29mm) ± .020” (.508mm) Rekluse thin friction disk minimum allowable thickness = 0.067” (1.70mm) EXP disk minimum allowable thickness = 0.416” (10.57 Measure EXP for allowable thickness 0.416”...
- Page 31 Need additional help? Contact Technical Support or visit our website for questions related to product installation, tuning, or performance issues. Website: www.rekluse.com/support Email: customerservice@rekluse.com Phone: (208) 426-0659 Doc ID: 198-6301010 Pg. 7 Doc Rev: 071117...
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