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Rekluse APEX Installation Manual

Harley-davidson big twins
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INSTALLATION GUIDE
Harley-Davidson
Big Twins
Doc ID: 191-7115005
Revision: 040824
©2024 Rekluse. All Rights Reserved.
customerservice@rekluse.com

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Summary of Contents for Rekluse APEX

  • Page 1 INSTALLATION GUIDE Harley-Davidson Big Twins Doc ID: 191-7115005 Revision: 040824 ©2024 Rekluse. All Rights Reserved. customerservice@rekluse.com...

  • Page 2: Table Of Contents

    PREPARE BIKE FOR INSTALLATION ......... 5 DISASSEMBLE CLUTCH .............. 6 INSPECT THE BASKET ..............7 REMOVE THE CLUTCH HUB ............7 INSTALL THE REKLUSE HUB ............. 9 INSTALL THE BASKET SLEEVES ..........10 INSTALL THE CLUTCH PACK ........... 11 INSTALL THE PRESSURE PLATE..........11 INSTALL THE CLUTCH SPRINGS ..........

  • Page 3: Overview

    • OE clutch pack (frictions and drive plates) • OE clutch hub • OE pressure plate and springs The Apex Clutch replaces the OE assist and slip clutch. Eliminating the assist and slip clutch provides better modulation and a superior clutch lever feel.

  • Page 4: Installation Tips

    Motorcycles with taller gearing or modified engines with increased horsepower o Customers looking for a lighter lever pull • For optimal clutch performance, Rekluse recommends using fresh, clean oil that meets JASO-MA oil rating requirements. Rekluse offers Factory Formulated Oil™ developed specifically for Rekluse products.

  • Page 5: Prepare Bike For Installation

    PREPARE BIKE FOR INSTALLATION 1. Stand the bike up on a lift or suitable bike stand. 2. Remove the oil drain plug and drain the oil into a suitable container. 3. Remove any parts that are attached or blocking the primary chaincase cover.

  • Page 6: Disassemble Clutch

    DISASSEMBLE CLUTCH ® 1. Soak the TorqDrive friction disks in new primary chaincase oil for 5 minutes. Make sure the friction disks are coated on both sides. 2. Remove the following OE parts. You may need to use dental pick tools to reach and remove the bottom plates and damper (judder) spring/seat.

  • Page 7: Inspect The Basket

    INSPECT THE BASKET Failure to inspect the basket and replace it if necessary could result in death, serious injury, and/or property damage. Inspect the clutch basket for notching. Do not install sleeves or use products with a notched basket. Notched basket tang faces can cause the sleeves to break.
  • Page 8 2. Remove the right-hand thread compensator bolt Note: A brace between the compensator and clutch basket sprockets will be required to keep them from spinning. 3. Remove the chain tensioner 4. Remove the basket & hub assembly along with the primary chain and the compensator sprocket 5.

  • Page 9: Install The Rekluse Hub

    INSTALL THE REKLUSE HUB 1. Press the Rekluse hub into the basket. Do not press directly on the aluminum hub, only on the steel washer in the center. Note: It can be helpful to set the hub nut onto the hub when pressing it to give the press something to contact.

  • Page 10: Install The Basket Sleeves

    6. Install the primary chain tensioner and torque to 21-24 ft-lbs. INSTALL THE BASKET SLEEVES 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.

  • Page 11: Install The Clutch Pack

    INSTALL THE PRESSURE PLATE 1. Remove the snap ring and bearing assembly from the OE pressure plate and install them into the Rekluse pressure plate. Ensure that the snapring seats properly into the groove. Note: The centerpiece may look different from the image above.

  • Page 12: Install The Clutch Springs

    Note: The OE clutch is rated to hold approximately 125 ft-lbs of engine torque. Twin Cam Models (07-16) 1. Install the Rekluse pressure plate springs, screw sleeves, and screws. Be sure to alternate springs if mixing colors. 2. Torque the pressure plate screws to 9 lb-ft (12 N-m).

  • Page 13: Set Freeplay (Cable Bikes Only)

    SET FREEPLAY (CABLE BIKES ONLY) Cable-actuated bikes must set the proper lever freeplay. Hydraulic-actuated bikes skip to the next section. Collapsing the Cable on an M8 1. Slide the black cover off the cable adjuster. 2. Unlock the red tab with a screwdriver. 3.

  • Page 14: Collapsing The Cable On A Twin Cam

    Collapsing the Cable on a Twin Cam 1. Loosen the jam nut on the inline cable adjuster 2. Collapse the inline cable adjuster completely 3. Check that the clutch lever has a large amount of free play. It should easily flop back and forth.
  • Page 15 2. Turn the adjuster screw COUNTERCLOCKWISE until it spins freely 3. Next, gently turn the adjuster screw CLOCKWISE until it stops under moderate pressure. • You are feeling for the point at which the screw bottoms out and starts to lift the pressure plate. This position is called your starting point.

  • Page 16: Resetting Cable Freeplay On An M8

    Resetting Cable Freeplay on an M8 1. Release the red tab on the cable adjuster so that the spring expands, then press the red tab to lock the adjuster in place. 2. Check that the lever has the proper 1/16-1/8” of freeplay Resetting Cable Freeplay on a TwinCam 1.

  • Page 17: Install The Primary Cover

    6. Using a funnel, add 1 liter of appropriate oil to the primary case through the derby cover cavity. Rekluse offers Factory Formulated Oil specifically for the V- Twin primary. 7. Reinstall the derby cover and torque bolts to 84-108 in-lbs.

  • Page 18: Break In The New Clutch

    • Use oil recommended by the manufacturer of your bike. • For optimal clutch performance, Rekluse recommends using fresh, clean oil that meets JASO-MA or MA2 standards. • Inspect all of your clutch parts for signs of wear or excessive heat, and replace components as necessary.

  • Page 19: 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 on 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 20: Troubleshooting

    • For cable bikes: Check that the cable freeplay is set properly. Excessive freeplay may cause drag. • Put in new Rekluse recommended oil. Old or improper oil can cause performance issues. • Check the clutch pack for signs of excessive heat or warpage.

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