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Related Manuals for Rekluse Motor Sports RadiusCX Clutch
Summary of Contents for Rekluse Motor Sports RadiusCX Clutch
- Page 1 INSTALLATION & USER’S GUIDE RadiusCX Clutch For KTM/Husqvarna CSS clutches Doc ID: 191-7902A Revision: 040919 ©2017 Rekluse Motor Sports 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 INSTALL THE HUB ................... 8 CLUTCH PACK INSTALLATION ............... 9 PRESSURE PLATE INSTALLATION ............14 SLAVE CYLINDER INSTALLATION ............17 Step 1: Bleed the new slave cylinder ......... -
Page 3: Overview
OVERVIEW This kit replaces many of the OE (Original Equipment) clutch parts while reusing some of the OE clutch parts. The following is a summary of what is replaced and what is reused: All OE steel drive plates will be replaced with Rekluse TEC ·... -
Page 4: Tools Needed
· Bikes with taller gearing or modified engines with increased horsepower may require heavier wedges. These can be purchased separately from Rekluse. TOOLS NEEDED 5 mm 8 mm 27 mm 4 mm Allen Wrench 5 mm Allen Wrench 8 mm Socket 27 mm Socket No Tools Torque Wrench... -
Page 5: Included Parts
INCLUDED PARTS Item Description Qty. Pressure Plate EXP Bases Steel Lining Plate Clutch Cover Center Hub Lock Tab Washer Fastener - 1/4-Turn Pin EXP Adjustment Spring (extra adjustment springs are included, see last page for EXP 60.X tuning options) Steel Drive Plate 8 or 9* ®... -
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. 8 mm Doc ID: 191-7902A Pg. - Page 7 4. Use an 8 mm socket to remove the following OE parts. See following picture for reference. 8 mm · 6 pressure plate bolts and · Center clutch nut and washer springs · 12 drive pins · Pressure plate · Clutch pack ·...
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Page 8: Install The Hub
5. Use a hammer and large screwdriver to bend down the tabs of the washer tab, then remove the center clutch nut with an impact wrench or breaker bar, and a 27 mm 27 mm socket. 6. Remove the tab washer, then remove the hub. INSTALL THE HUB 1. -
Page 9: Clutch Pack Installation
4. Bend up both tabs of the tab washer using channel-lock pliers. 5. Seat the 6 OE drive pins into the Rekluse outer hub. Channel-lock Pliers CLUTCH PACK INSTALLATION Each clutch pack comes with a set of steel plates, a set of friction disks, and an EXP disk. - Page 10 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 drive plate first. Hold a TEC drive plate so that the “shark fin”...
- Page 11 3. Align the drive pin notches in the TEC drive plate with the drive pins on the hub, then install the drive plate into the basket. Be sure that the drive pins are seated in the notches and not in the bigger sections. ALL the TEC plates must be aligned in the drive pins notches or damage may occur.
- Page 12 4. On top of the steel drive plate, install a Rekluse friction disk. Continue to alternate steel drive plates and friction disks for the entire clutch pack. Some friction disks are marked with a small colored dot. This mark is used for processing and can be ignored.
- Page 13 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. 6. Reinstall the OE throw-out. Pg. 13 Doc ID: 191-7902A Doc Rev: 040919...
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Page 14: Pressure Plate Installation
PRESSURE PLATE INSTALLATION 1. Add a light film of oil between the lining plate and pressure plate. This will help the plates stick together for ease of installation. 2. Install the supplied lining plate onto the Rekluse pressure plate by lining up the index tabs into the slots. 3. - Page 15 4. Place the pressure plate springs into the assembled clutch, then insert the screw sleeves into the springs. 5. Insert the pressure plate bolts into the screw sleeves. Do not reuse the OE springs, or clutch cover interference will occur! 6.
- Page 16 7. Install the OE cover gasket onto the Rekluse clutch cover. 8. Install the Rekluse clutch cover by lightly tightening the cover bolts in a star pattern. Tighten bolts in small increments before torquing the cover bolts to Torque Wrench OE specifications.
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Page 17: Slave Cylinder Installation
SLAVE CYLINDER INSTALLATION Installing the new Rekluse slave cylinder takes several steps. Please read the entire section before beginning the process to ensure you have the right equipment and clutch fluid needed for the replacement. Rekluse recommends wearing gloves and safety glasses for the install. - Page 18 2. Use your thumbs to compress the piston until it bottoms out, then release it. Pour the recommended clutch fluid into the slave cylinder port. Be sure to use the correct clutch fluid. Check the cap of the clutch master cylinder to determine which clutch fluid to use. Failure to use the correct fluid will result in seal damage and/or failure.
- Page 19 5. Use the wrench to turn the adjuster screw counterclockwise back to the initial position, with the top O-ring visible. Keep the fluid topped off as you go. 6. Use your thumbs to compress the piston again until it bottoms out while looking for air bubbles.
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Page 20: Step 2: Replace Oe Slave Cylinder
10. Check that the ball bearing is still in place. Stand the Rekluse slave cylinder in an upright position (so that the fluid does not spill) until it is needed in the next step. Step 2: Replace OE slave cylinder In this step, the OE slave cylinder is replaced with the Rekluse slave cylinder. - Page 21 2. On the left side of the bike, while leaving the OE slave cylinder intact on the engine, use a wrench to remove the banjo bleeder bolt from the OE Slave cylinder. 3. Separate the OE slave cylinder from the clutch fluid line. 4.
- Page 22 2016 FC450 and 2017+ FC450/501 OWNERS: Use the supplied banjo bleeder bolt in place of the OE banjo bolt. Insert bleeder bolt into Rekluse slave cylinder in the same orientation as it was in the OE slave cylinder 6. Tighten the banjo bolt with your hand until snug. (You will torque it to spec once installed on the bike.) 7.
- Page 23 The Rekluse slave cylinder comes preassembled in the kit. If the parts are separated, assemble them in the following order: Rekluse slave cylinder, O-ring (the one supplied or OE), then the supplied paper gasket. Not all slave cylinders come with a gasket. If not supplied, use the OE gasket.
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Page 24: Bleed The Clutch Line
Optional: If you purchased the Rekluse Slave Guard accessory, install it now using the specific instructions included with the slave guard kit. BLEED THE CLUTCH LINE 1. Attach one end of the supplied bleed tube to the banjo bolt port, then loop the opposite end into a suitable catch bottle. - Page 25 3. Top off the master cylinder with the recommended clutch fluid until it is 75% full. 4. Pump the clutch lever 3 to 5 times, then hold it against the handlebar/grip. 5. While still holding the clutch lever in, use a wrench to open the bleed port.
- Page 26 7. Slowly release the clutch lever and check the fluid level in the clutch master cylinder. Top off if necessary. 8. Repeat steps 4 - 7 until air no longer comes out of the bleed tube and the clutch feels normal. 9.
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Page 27: 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 28: 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 29: Step 2: Learn How To Check Free Play Gain
Use the tick marks on the cylinder and the etch mark on the screw to remember the starting point for adjusting the gap. d) Use a 4 mm Allen wrench to turn the adjuster screw clockwise 1 full turn + 2 tick marks from your starting point. This may NOT be your final setting, but it is a beginning adjustment for finding the correct setting. - Page 30 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 31: 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 32 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 33 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 34: The Hand Method
f) When the bike 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 Use the hand method to check Free Play Gain before the start of every ride for optimum performance and longevity of your new clutch. - Page 35 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 36: 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 37 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 38: 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 should be... - Page 39 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 40: 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 screw Play Gain) -
Page 41: Maintenance
MAINTENANCE To keep your clutch performing at its best, perform regular maintenance on your bike and clutch. · Keep up with regular oil changes as per the bike manufacturer’s recommendations. 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. - Page 42 Calipers · 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 43: Disk Inspection Examples
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 44: Troubleshooting
TROUBLESHOOTING Performance issues If you find yourself adjusting the slave cylinder to fix Free Play Gain or drag, the clutch disks might be worn. Excessive heat or clutch slip can cause premature clutch failure as well. Once extreme temperatures are reached, irreversible damage will occur. ·... -
Page 45: Changing The Springs
gear and warmed up. The idle should not be so high as to move the bike forward in gear with the throttle closed. However, with a small opening of the throttle the bike should move forward. You can tune the engagement RPM of the EXP disk by changing the spring configuration. - Page 46 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. If you disassemble the EXP, the Teflon pads may fall out or be stuck to the ramp surfaces of the EXP bases.
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Page 47: Configuration Chart
Configuration chart ENGAGEMENT SPRING CONFIGURATION SETTING 350SX-F/XC-F All Others 6 Silver 3 Silver & 3 Red Medium 3 Red & 3 Silver 6 Red Medium High 6 Red High 3 Red & 3 Blue 3 Red & 3 Blue BUMP-STARTING If your bike needs to be bump-started due to a dead battery or any other reason, follow the steps below to quickly bump-start your bike. -
Page 48: 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. Technical Support hours: Monday thru Friday: 8:00 a.m. - 5:00 p.m. Mountain Time zone Email: tech@rekluse.com Customer Service... - Page 49 Auto Clutch TROUBLESHOOTING GUIDE Rekluse Troubleshooting Guide Terms Free Play Gain – The additional movement of the clutch lever under slight pressure as the RPMs are raised from idle to approximately 5000 RPM. Free Play Gain should only be checked in neutral as per the instructions.
- Page 50 Note: The “possible fixes” contained in the chart below are listed in the order of things to try first for each “symptom” Core EXP 3.0 & EXP 3.0 Troubleshooting Chart Symptom Possible Cause Possible Fix Clutch break-in Complete the recommended clutch break-in Change the oil if it’s not a clean high quality JASO MA certified Transmission oil Excessive “Free Play Gain”...
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