Related Manuals for Rekluse RadiusX FTR 1200
Summary of Contents for Rekluse RadiusX FTR 1200
- Page 1 INSTALLATION & USER’S GUIDE RadiusX Indian FTR 1200, FTR Rally, & FTR 1200 S DocID:191-6216200A ©2019 Rekluse Motor Sports Revision: 081720 Rekluse Motor Sports, Inc. customerservice@rekluse.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS OVERVIEW ................3 INSTALLATION TIPS ............3 TOOLS NEEDED ..............4 INCLUDED PARTS ............... 5 DISASSEMBLE THE CLUTCH ..........6 CLUTCH PACK INSTALLATION ......... 10 Notes for installation ............10 Clutch pack ..............10 PRESSURE PLATE INSTALLATION ........13 PRIMARY COVER INSTALLATION ........ -
Page 3: Overview
Rekluse-designed high quality clutch pack designed specifically for your bike model. The following is a summary of what is replaced: · All OE steel drive plates will be replaced with Rekluse drive plates · All OE friction disks will be replaced with Rekluse ®... -
Page 4: Tools Needed
TOOLS NEEDED · 4mm allen wrench · 5mm allen wrench · 6mm allen wrench · 8mm socket · 10mm socket · 12mm socked · 12mm wrench · Torque wrench in-lb · Torque wrench ft-lb · Picks · Fluid catch container Doc ID: 191-6216200A Pg. -
Page 5: Included Parts
Basket Sleeves EXP Wedges Not Shown Velcro straps Not Shown Orange Free Play Gain rubber band Not Shown Clutch lever warning label Visit www.rekluse.com/support for a full parts fiche illustration and part numbers. Pg. 5 Doc ID: 191-6216200A Doc Rev: 081720... -
Page 6: Disassemble The Clutch
DISASSEMBLE THE CLUTCH 1. Stand the bike up on a suitable bike stand or lift. 2. Drain the engine oil into a suitable container by removing the two oil drain plugs. 3. Remove the center exhaust heat sheild. Doc ID: 191-6216200A Pg. - Page 7 4. Remove the front exhaust heat sheild. 5. Unplug the oxygen sensor connector from the front header pipe. 6. Remove the head pipe fasteners securing the head pipe to the cylinder head. 7. Loosen the two exhaust clamps securing the front and rear header pipes.
- Page 8 9. Remove the jam nut from the clutch cable housing and pull the housing out from the engine case. Remove the clutch cable from the actuator arm. 11. Remove the primary cover bolts. 12. Remove the primary cover. Doc ID: 191-6216200A Pg.
- Page 9 13. Remove the following clutch components: pressure plate bolts, spring ring, springs, pressure plate, clutch pack, judder spring, and judder spring seat. clutch pack judder spring seat Pack springs bolts spring ring pressure plate judder spring Pg. 9 Doc ID: 191-6216200A Doc Rev: 081720...
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Page 10: Clutch Pack Installation
· The OE basket has “half slots” at the top of the basket tangs. This Rekluse product requires the entire clutch pack be installed into the MAIN (deeper) basket slots. Installing the clutch pack into the “half slots” will cause performance issues. - Page 11 3. Install ALL the Rekluse basket sleeves into the basket slots. Make sure the sleeve tabs sit against the inside of the basket, then push the sleeves down until they contact the bottom of the tang slot.
- Page 12 4. Install a TorqDrive friction disk followed by a 0.40” drive plate. 5. Continue to alternate the remaining 4 TorqDrive friction disks with 4 of the 0.040” steel drive plates. 6. On top of the last drive plate, install the EXP assembly. 7.
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Page 13: Pressure Plate Installation
PRESSURE PLATE INSTALLATION 1. Turn the pressure plate over onto a work bench. Place one .150” thick friction disk on to the pressure plate. 2. Next place the .065” drive plate on to the pressure plate and place the last .150” thick friction disk. 3. - Page 14 4. Install the Rekluse pressure plate springs, followed by the OE spring ring and bolts. 5. Evenly tighten the bolts, then torque the bolts to 80 in-lb (9 N-m). Doc ID: 191-6216200A Pg. 14 Doc Rev: 081720...
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Page 15: Primary Cover Installation
PRIMARY COVER INSTALLATION 1. Clean the gasket surface of the crankcase and primary cover. NOTE: If the primary gasket was damaged during disassembly it will be necessary to replace the gasket. (Indian part # 5416661 GASKET, PRIMARY COVER AP) 2. When reinstalling the primary cover, make sure that the clutch rack is angled so the clutch shaft will align and slowly place the cover onto the engine case. - Page 16 5. Reattach the clutch cable to the actuator arm. 6. Reinstall the clutch cable to the engine case, but do not adjust the cable, cable adjustment will occur when setting Free Play Gain. 7. Reinstall both oil drain plugs, torque to 15 ft-lbs (20 Nm) and fill with oil to factory specifications (oil and filter change approximately 4 US quarts).
- Page 17 12. Install the front exhaust heat sheild and torque the fasteners to 88 in-lbs (10 Nm). 13. Install the center exhaust heat sheild and torque the fasteners to 88 in-lbs (10 Nm). Pg. 17 Doc ID: 191-6216200A Doc Rev: 081720...
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Page 18: Set The Installed Gap
SET THE INSTALLED GAP The “installed gap” is the separation in the clutch pack created by the tension adjusted into the clutch cable. This gap is what allows the clutch to spin freely until the desired RPM is reached for engagement. The installed gap must be set correctly. -
Page 19: 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 20 Lever position Lever with “slack” th “slack” around 2,000 RPM removed Free Play Gain e Pl 1/8”-1/4” (3 mm-6 mm) lever movement · If there is too much Free Play Gain, the installed gap is too small. o The vehicle may drag and stall because it has difficulty disengaging the clutch.
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Page 21: 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 22 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.
- Page 23 e) While still in NEUTRAL, quickly rev the engine between 2,000-2,500 RPM (1/4 to 1/2 throttle), then let it return to idle. Notice the movement in the clutch lever when the engine is revved. This is your Free Play Gain. Note: It is very important the motor returns to idle before revving the engine again or Free Play Gain will not be correct.
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Page 24: 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 vehicle in NEUTRAL, start the engine and let it warm up for 2-3 minutes to idle down and warm up the engine oil. -
Page 25: 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 “SHIFTING AND OPERATION” If Free Play Gain is not optimal, the installed gap needs to be adjusted. -
Page 26: Break In The New Clutch
Reduce the length of · Too little Free Play the cable housing Gain: Clutch lever (collapse the only moves slightly adjusters) until the or does not move Installed gap correct amount of at all is too large freeplay gain is ·... - Page 27 2. With the engine still running, pull in the clutch lever, then shift the vehicle into 1 gear. Slowly release the clutch lever. The vehicle should stay running and in place or have a slight amount of forward creep. 3. With the vehicle idling in first gear, slowly apply throttle to 15 roll-on starts begin moving.
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Page 28: 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. For other EXP tuning options, see the Setup sheet at the back of the Installation Manual. -
Page 29: Changing The Exp Springs
Changing the EXP springs Use the following steps to change the EXP spring configuration. It is NOT necessary to disassemble the EXP halves to change 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 30: Shifting And Operation
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. SHIFTING AND OPERATION · Always use proper gear selection for the speed and situation whether accelerating or slowing down. - Page 31 Pg. 31 Doc ID: 191-6216200A Doc Rev: 081720...
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Page 32: Maintenance
· Measuring the friction disks for wear. This can help determine if the components need replacing. o Rekluse thin friction disk minimum allowable thickness = 0.068” (1.7 mm) · Replace friction disks if they measure below specifications or if the disks are glazed and/or burnt. - Page 33 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. See pictures below. Not all drive plates look the same and may look different than pictured. Normal Heat High Heat Excessive Heat...
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Page 34: Troubleshooting
TROUBLESHOOTING Clutch Drag · Cold Drag Only – Cold drag is normal. The clutch will usually have some amount of drag before the oil warms to operating temperature. Be sure to warm up the vehicle before riding. · Hot and Cold Drag – Change oil. Check for warped or non-flat drive plates in the clutch pack. -
Page 35: Need Additional Help
Contact Technical Support for questions related to product installation, tuning, and performance. Technical Support 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. Customer Service hours: Monday thru Friday: 8:00 a.m.
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