Related Manuals for Rekluse RADIUSX
Summary of Contents for Rekluse RADIUSX
- Page 1 INSTALLATION GUIDE For Harley-Davidson Big Twin Cable Actuated Doc ID: 191-6203A Revision: 100219 ©2015 Rekluse Motor Sports Rekluse Motor Sports, Inc. customerservice@rekluse.com...
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Page 2: Table Of Contents
This kit replaces the OE (Original Equipment) or “stock” clutch pack. · This kit will replace all the OE frictions, drive plates, and spring ring ® with a Rekluse TorqDrive clutch pack and EXP disk. · No modification of the OE parts are necessary. -
Page 3: Installation Tips
· Use the torque values listed in the instructions. Otherwise, use the torque specifications found in your OE service manual. · Visit www.rekluse.com/support for a full parts fiche illustration and part numbers. · For optimal clutch performance Rekluse recommends using fresh, clean oil that meets JASO-MA oil rating requirements. -
Page 4: Included Parts
INCLUDED PARTS Item Description Qty. EXP bases Wedge assembly Quarter-turn pins (extra included) 60.1, 60.2 EXP adjustment springs – colors vary Spring ring hold down plate Steel drive plate - .040” (1 mm) thick Steel drive plate - .065” (1.6 mm) thick ®... -
Page 5: Before You Begin
Belleville spring options Typically, the OE Belleville spring is reused when installing a Rekluse auto clutch. However, if the bike has a highly modified engine, and the OE clutch did not provide enough torque capacity, alternate springs can be purchased to optimize the clutch setup. -
Page 6: Disassemble Clutch
heat during regular use, and thus may cause premature wear, slip, or poor performance. Installing a higher-force spring can significantly improve clutch life and performance by reducing this heat. DISASSEMBLE CLUTCH 1. Make sure the bike has cooled before disassembling the clutch. ®... - Page 7 4. On the primary chain case, use a 5/8” wrench to remove the oil drain plug, then drain the oil. 5. Remove any parts that are attached or blocking the primary chaincase cover. These may include the left floorboard, foot peg(s), shift lever, and/or the side stand.
- Page 8 7. Remove the following OE parts: Pressure plate bolts Spring ring Belleville spring Pressure plate Clutch pack Damper (judder) spring and seat Note: Set aside the OE damper (judder) spring, damper seat, and Belleville spring. They will be reused. Doc ID: 191-6203A Pg.
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Page 9: Install The Clutch Pack
INSTALL THE CLUTCH PACK Notes for installation · When assembling the clutch pack, it is important to line up the alignment notches on the friction disk tabs. Correct alignment is critical for optimal performance. Align notches of friction disks · Some friction disks are marked with a small colored dot. This mark is used for processing and can be ignored. - Page 10 2. Install ALL the Rekluse basket sleeves into the OE 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. See pictures for reference.
- Page 11 5.Add a Rekluse friction disk followed by a steel drive plate. Continue to alternate friction disks and drive plates for the entire clutch pack. Remember to align the notches on the friction disks when installing the clutch pack. Friction disks...
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Page 12: Install The Pressure Plate
EXP disk INSTALL THE PRESSURE PLATE 1. Fully collapse the in-line cable adjuster so that the cable slack makes the clutch lever very sloppy at the perch. Note: Adding cable slack ensures that the cable will not have excessive stress during the pressure plate adjustment. Doc ID: 191-6203A Pg. - Page 13 3. Remove the throw-out adjuster jam nut from the center of the pressure plate using an 11/16” socket. 4. Install the OE Belleville spring and the Rekluse spring ring, then install the OE pressure plate bolts. Pg. 13...
- Page 14 OE Belleville spring OE pressure plate bolts Rekluse spring ring 5. Using a 10 mm socket, torque the pressure plate bolts in a star pattern to 90-110 in-lbs (10–12.4 N-m). Doc ID: 191-6203A Pg. 14 Doc Rev: 100219...
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Page 15: Set The Installed Gap
SET THE INSTALLED GAP The installed gap is the separation in the clutch pack created by adjusting the Rekluse Adjuster Assembly. This gap is what allows the clutch to spin freely until the desired RPM is reached for engagement. The gap must be set correctly for optimal performance. - Page 16 3. From the starting point, turn the adjuster screw 1¼ turn CLOCKWISE to lift the pressure plate. Note: The ideal Installed Gap created by 1¼ turn past the starting point is about .035” (.89 mm). If desired, this can be measured using feeler gauges.
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Page 17: Primary Cover Installation
PRIMARY COVER INSTALLATION 1. Thoroughly clean the mating surfaces of the primary cover and the engine case. 2. Reinstall the primary gasket (or new gasket). 3. Reinstall the primary cover, then torque the cover bolts to 84-108 in-lbs (9.5-12.2 N- 4. -
Page 18: Reset The Lever Free Play
RESET THE LEVER FREE PLAY “Lever free play” is essentially the “slack” in the clutch cable before it starts actuating the clutch. Applying a light finger pressure will take up this slack. 1. Expand the in-line adjuster until the cable slack is between 1/16”... -
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 “ l k” around 4,000 RPM removed Free Play Gain 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 bike 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 Motorcycles equipped with a Rekluse auto-clutch can move suddenly and unexpectedly and cause riders to lose control. To avoid death, serious injury, and/or property damage, always sit on the motorcycle to start it. 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 the engine oil.
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Page 23: The Hand Method
e) While still in NEUTRAL, quickly rev the engine between 3,000-5,000 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. - Page 24 clutch lever when the engine is revved. This is your Free Play Gain. d) When the bike returns to idle, rev the engine between 3,000- 5,000 RPM a second time to verify the Free Play Gain again. Doc ID: 191-6203A Pg.
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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 “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 26: 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 27 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. Make necessary adjustments before proceeding. 5. Place the bike in NEUTRAL and recheck Free Play Gain. Continue to adjust the installed gap until the clutch lever is 1/8”-1/4”...
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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, based on an idle of RPM = 850 - 1050. If your idle is higher than 1050 RPM, it may be best to install the “High”... -
Page 29: Changing The Springs
Changing the springs 1. Using a flat-blade screwdriver, push the ¼ turn pin in far enough for the locking tab to push out of the locking collar. 2. With the pin still pushed past the locking collar, turn 90° to remove the pin and spring. - Page 30 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. 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 31: Lever Safety Straps
Technical Support hours: Monday thru Friday: 8:00 a.m. - 5:00 p.m. Mountain Time zone Phone: (208) 426-0659 Email: tech@rekluse.com · Additional contact information can be found in the User’s Guide. Pg. 31 Doc ID: 191-6203A Doc Rev: 100219...
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