Related Manuals for Rekluse RadiusCX Clutch Upgrade Kit
Summary of Contents for Rekluse RadiusCX Clutch Upgrade Kit
- Page 1 INSTALLATION & USER’S GUIDE RadiusCX Clutch Upgrade Kit For KTM/Husqvarna DDS clutches Doc ID: 191-7911A Revision: 080420 ©2017 Rekluse Motor Sports Rekluse Motor Sports, Inc. support@rekluse.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS OVERVIEW ..................3 INSTALLATION TIPS ..............3 Tuning Note .................. 4 TOOLS .................... 4 INCLUDED PARTS ................. 5 DISASSEMBLE THE CLUTCH ............6 INSPECT THE DAMPERS .............. 8 CLUTCH PACK INSTALLATION ............. 8 PRESSURE PLATE INSTALLATION ..........11 SET THE INSTALLED GAP AND VERIFY BY CHECKING FREE PLAY GAIN ................... -
Page 3: Overview
OVERVIEW This guide shows you how to replace your OE (Original Equipment) core clutch parts with your new Rekluse upgraded clutch parts. The following parts are replaced: · Core EXP 3.0 Drive Plates · OE Friction Disks INSTALLATION TIPS Read the safety information sheet included with your kit. -
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 ·... -
Page 5: Included Parts
INCLUDED PARTS Item Description Qty. TEC Steel Drive Plate TorqDrive Friction ® Visit www.rekluse.com/support a full parts fiche illustration and part numbers. Pg. 5 Doc ID: 191-7911A Doc Rev: 080420... -
Page 6: 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. 4. - Page 7 Be careful that the drive pins do not fall into the engine while disassembling. 5. Check that the 6 OE drive pins are still seated into the Rekluse outer hub. Pg. 7 Doc ID: 191-7911A Doc Rev: 080420...
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Page 8: Inspect The Dampers
2. Rotate the inner hub back and forth inside the outer hub. Rekluse recommends replacing the dampers if you feel any play between the two hubs – KTM part number #78132025100. - Page 9 1. Soak the friction disks and EXP disk in new oil for at least 5 minutes. Make sure the EXP and friction disks are coated on both sides. 2. Install a steel TEC drive plate by first aligning the drive pin notches in the plate with the drive pins on the hub.
- Page 10 Continue alternating the steel drive plates with the friction disks for the entire Rekluse clutch pack. Install the EXP disk on top of the last steel plate. Make sure that the EXP disk is seated in the same slots as the clutch pack.
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Page 11: Pressure Plate Installation
Some OE basket have “half slots” at the top of the basket tangs. Rekluse products require that the entire clutch pack, including the EXP disk, be installed into the MAIN (deeper) basket slots. 7. Check that the throw-out and thrust washer are still on the main shaft and not stuck to the bottom of the center hub assembly. - Page 12 3. Install the pressure plate subassembly by lining up the index tabs on the pressure plate with the slots in the hub. When the pressure plate is seated correctly, the threaded standoffs will come through the openings of the pressure plate. 4.
- Page 13 In most cases, this is the best starting point for the clutch. 7. Using the T-25 Torx bit and torque wrench, install the Rekluse pressure plate screws. Do not reuse the OE screws, or clutch cover interference will occur! Pg.
- Page 14 Tighten bolts in small increments before torquing the cover bolts to OE specifications. If your bike has an oil plug, transfer the OE oil plug to the new Rekluse clutch cover. Doc ID: 191-7911A Pg. 14...
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Page 15: Set The Installed Gap And Verify By Checking Free Play Gain
SET THE INSTALLED GAP AND VERIFY BY CHECKING FREE PLAY GAIN 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 16: Step 1: Find The Starting Point
Setting the installed gap and checking Free Play Gain is a 4-step process. It is important to follow each step to ensure that your new clutch functions as designed. Step 1: Find the starting point a) With the bike standing up, locate the adjuster screw in the center of the adjustable slave cylinder. -
Page 17: Step 2: Learn How To Check Free Play Gain
Free Play Gain is different from the “normal” free play you are used to with your stock clutch. With the Rekluse auto clutch, Free Play Gain is the result of the EXP disk expanding and lifting the pressure plate to engage the clutch. - Page 18 installed gap. The amount of Free Play Gain you feel in the lever corresponds to the amount the pressure plate has been lifted by the EXP disk expansion. 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.
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Page 19: 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 20 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.
- Page 21 d) Pull the band through the loop, then attach it to the outside end of the clutch lever. This will take up the initial free play (slack) and put the lever in a position to detect the Free Play Gain. e) While still in NEUTRAL, quickly rev the engine between 5,000- 7,000 RPM (1/2 to ¾...
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Page 22: The Hand Method
Free Play Gain. Failure to do so may result in the bike lurching forward, and loss of control and/or injury may result. 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. - Page 23 b) With the bike at idle, apply enough pressure to the clutch lever to take up the initial free play (slack) in the clutch lever. c) While still in NEUTRAL, continue to apply light pressure and quickly rev the engine between 5,000-7,000 RPM (1/2 to ¾ throttle), then let it return to idle.
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Page 24: Step 3: Break-In The New Clutch
The lever may move more than 1/8” (3 mm) toward the handle when the engine is revved because there is too much Free Play Gain (movement of the clutch lever). This changes as you adjust the installed gap. Step 3: Break-in the new clutch Once you install your new clutch, it is important to break it in. - Page 25 3. With the engine still running, pull in the clutch lever, then click the bike into 1 gear. Slowly release the clutch lever. The bike should stay in place or have a slight amount of forward creep. 4. With the bike idling in first gear, slowly apply throttle to begin moving.
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Page 26: 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” (3 mm). Recheck Free Play Gain and adjust the installed gap Your clutch pack will expand with heat, so final adjustment to Free Play Gain... - Page 27 Tick marks are located on the slave cylinder, and an etch mark is on the screw. If you need to re-position the Allen wrench, you can use these marks for reference. c) Continue to adjust the slave cylinder 1 tick mark at a time until optimal Free Play Gain is achieved.
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Page 28: 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” (3 mm) of clutch lever movement. Symptom Reason Solution · Clutch lever moves in too far (too much Free Turn the adjuster Play Gain) -
Page 29: Maintenance
Clutch performance and longevity depend on oil quality. Oil recommendations can also be viewed under Tech Tips on our website at www.rekluse.com/support/videos/atv-mc-support- videos. · Inspect all of your clutch parts for signs of wear or excessive heat, and replace components as necessary. Clutch wear is dependent on the riders use. - Page 30 · Inspect the dampers, and replace them if you feel any movement between the two hubs. Refer to the section on inspecting the dampers for more information. · Maintain adequate Free Play Gain. Check before every ride and adjust if necessary. ·...
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Page 31: 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 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 32: Troubleshooting
For bike models that have clutch squeal or chatter here are some recommendations to reduce or eliminate it: · Change the oil: For optimal clutch performance Rekluse recommends using fresh, clean oil that meets JASO-MA oil rating requirements. Dirty or old oil can make the clutch more likely to squeal or chatter. -
Page 33: Changing The Springs
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. Use the following steps to change the springs. It is NOT necessary to disassemble... - Page 34 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. 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 35: Configuration Chart
place once the EXP is reassembled. Operating the clutch without the pads in place will cause part damage or failure. Configuration chart ENGAGEMENT SPRING CONFIGURATION SETTING 450/500/501 250/300 250/300 250/350 4-stroke 2-stroke 2-stroke EXC-F/ (Pre 2017) (2017+) XCF-W 3 Silver & 3 6 Silver 6 Blue 6 Silver... -
Page 36: Need Additional Help
Technical Support hours: Monday, Tuesday, Wednesday, and Friday: 8:00 a.m. - 5:00 p.m. Thursday: 8:00 a.m. – 4:30 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, Tuesday, Wednesday, and Friday: 8:00 a.m. - Page 37 High RPM Slip – Occurs above half throttle while accelerating, as the engine RPMs raise little or no power is transmitted to the rear wheel resulting in a loss of forward drive causing excessive clutch heat *Rekluse troubleshooting chart located on back of this page* Doc ID: 193-707A...
- Page 38 Change the oil if it’s not clean high quality JASO MA certified Transmission oil oil. Over-used oil may cause squeal or chatter Replace the basket and/or cushions if they are worn (Rekluse Squeal or Chatter basket recommended if available for your model)
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