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Rekluse RadiusX Clutch Installation & User Manual

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INSTALLATION & USER'S
GUIDE
RadiusX Clutch
for Cable Actuated Bikes and ATVs
Doc ID: 191-6300B
Revision: 101722
©2021 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
customerservice
@rekluse.com

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  • Page 1 INSTALLATION & USER’S GUIDE RadiusX Clutch for Cable Actuated Bikes and ATVs Doc ID: 191-6300B Revision: 101722 ©2021 Rekluse Motor Sports Rekluse Motor Sports, Inc. customerservice @rekluse.com...

  • Page 2: Table Of Contents

    Changing the EXP Springs ..........21 BREAKING-IN THE NEW CLUTCH ........23 OPTIMIZING THE CLUTCH LEVER ......... 25 Optimization with OE Perch Adjuster ......25 Optimizing the Rekluse Adjustable Reach Lever ... 26 MAINTENANCE ..............27 Clutch Wear ..............27 Clutch Parts ..............28 Basket ................

  • Page 3: Installation Tips

    OE (Original Equipment) components with high- quality Rekluse components. • The OE friction disks and drive plates will be replaced with a Rekluse thin friction EXP clutch pack. • The OE pressure plate springs will be replaced with Rekluse springs.

  • Page 4: Tools Needed

    OEM or aftermarket wet clutch. Visit www.rekluse.com learn more. • This clutch pack is not legal to race with in the AMA Limited or Stock class. TOOLS NEEDED 10 mm Metric Torque 8 mm socket socket Wrench Wrench 4 mm...

  • Page 5: Disassembling The Clutch

    DISASSEMBLING THE CLUTCH 1. Soak the Rekluse friction disks in new oil for at least 5 minutes. Make sure the friction disks are coated on both sides. 2. If applicable, turn the fuel petcock to “OFF.” 3. For bikes, lay the bike on its left side. Catch any fluids that might drain into a suitable container.
  • Page 6 4. Remove the OE clutch cover and set it aside. It will be reused. 5. Remove the OE pressure plate bolts, springs, and pressure plate. Set them aside; they may be reused. Note: Throw-out washers can stick to the back of the pressure plate.
  • Page 7 Note: Some models have a judder spring (clutch boss spring), a spring seat, and a narrow friction located in the bottom of the OE friction pack. If your model is equipped with these parts, remove them and set the spring aside. Refer to the included Setup Sheet to determine if your model reuses any of these parts.

  • Page 8: Installing The Cluck Pack

    Notes for Clutch Pack Installation • Some OE baskets have “half slots” at the top of the basket tangs. Rekluse products require the entire clutch pack be installed into the MAIN (deeper) basket slots. Do not use the “half slots” (see below).
  • Page 9 Note: If the basket is notched or worn, Rekluse recommends replacing it with a Rekluse Billet Clutch Basket (available for most models). • Inspect your OE center hub and pressure plate flanges for excess wear. If wear is visible use a drop gauge to verify that the wear across the flange does not exceed .005”...

  • Page 10: Install Clutch Pack

    Install Clutch Pack 1. Install all of the Rekluse basket sleeves into the basket slots. Make sure the bottom of the sleeve is facing down, and the sleeve tabs sit against the inside of the basket. Sleeve tabs sit inside the...
  • Page 11 4. If your kit includes a Rekluse throw-out spacing washer, install it on top of your OE throw-out as indicated by the included Setup Sheet. Suzuki RM-Z450 Models: The needle bearing only has the bearings on one side. Make sure that the bearing side is facing the throw-out and the flat side is facing the pressure plate.
  • Page 12 5. Reinstall the pressure plate, then install the Rekluse pressure plate springs and OE bolts. Note: For Yamaha YZ250F (2019+), YZ250FX (2020+), & WR250F (2020+) when installing the pressure plate align the indent in the pressure plate with the indent in the center hub.
  • Page 13 Note: DRZ 400, KLX 400, KX 500 bike models: If your kit includes Rekluse screw sleeves or spring bolts, install them in place of the OE components. The DRZ 400 and KLX 400 models will utilize the supplied Rekluse screw sleeves and OE bolts, and KX 500 models will utilize supplied Rekluse screw sleeves and Rekluse bolts.
  • Page 14 Doc ID: 191-6300B Pg. 14 Doc Rev: 101722...

  • Page 15: Setting The Installed Gap

    If Free Play Gain is new to you, follow the instructions below. You can also view the video titled “How to Check Free Play Gain” on our website at www.rekluse.com/support/videos. Optimal Free Play Gain yields 1/8”-1/4” (3 mm-6 mm) of clutch lever movement, measured at the ball end of the lever.

  • Page 16: Two Methods To Check Free Play Gain

    Two Methods to Check Free Play Gain There are two ways to check for 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 17: The Hand Method

    c) While holding the top end of the rubber band against the handlebar, stretch the band downward, and then loop it through itself. d) Pull the band through the loop, and then attach it to the outside end of the clutch lever. e) While still in NEUTRAL, quickly rev the engine between 5,000-7,000 RPM (1/2 to ¾...
  • Page 18 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. Notice the movement in the clutch lever when the engine is revved. This is your Free Play Gain. d) When the bike/ATV returns to idle, rev the engine between 5,000-7,000 RPM a second time to verify the Free Play Gain again.

  • Page 19: Adjusting The Installed Gap

    ADJUSTING THE INSTALLED GAP After checking for Free Play Gain, you may need to adjust the installed gap. If the Free Play Gain is optimal, continue to “Breaking-In the New Clutch”. If the 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 20 Adjust the Installed Gap Solution Symptom Reason • Clutch lever moves Tighten the cable: in too far (too increase the length much Free Play of the in-line cable Gain) adjuster housing Installed gap until the correct • Clutch has is too small amount of Free Play excessive drag or Gain is achieved.

  • Page 21: Tuning The Exp

    TUNING THE EXP This kit includes multiple spring settings to adjust the engagement RPM of the EXP friction disk. The EXP friction disk comes preinstalled with the recommended “Medium” setting. See the included Setup Sheet for a chart of the available EXP spring configurations.
  • Page 22 Doc ID: 191-6300B Pg. 22 Doc Rev: 101722...

  • Page 23: Breaking-In The New Clutch

    BREAKING-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 steps for breaking in your clutch and any time new friction disks, EXP bases, Teflon pads, or wedges are installed.
  • Page 24 5. Without using the clutch lever, accelerate moderately to approximately 5,000 RPM to fully lock up the clutch and come to a complete stop. Repeat 10 times. 10 roll-on starts 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.

  • Page 25: Optimizing The Clutch Lever

    OPTIMIZING THE CLUTCH LEVER If your bike model is not equipped with a perch adjuster bolt, you may purchase, as an option, a Rekluse Adjustable Reach Lever. Optimization with OE Perch Adjuster Kits for Honda the CRF 450 and CRF 250 include a new perch adjuster bolt.

  • Page 26: Optimizing The Rekluse Adjustable Reach Lever

    Optimizing the Rekluse Adjustable Reach Lever Set the clutch lever to the desired reach point while maintaining clutch lever slack. • Turning your adjuster bolt farther in will push the lever farther from the bar and allow for a further reach point.

  • Page 27: Maintenance

    ATV and clutch. Clutch Wear Rekluse clutches are built using high quality materials but do wear based on the rider’s use, type of terrain, and natural wear and tear. To keep your clutch performing at its best, perform regular maintenance on your bike/ATV and clutch based on your riding style.

  • Page 28: Clutch Parts

    Clutch Parts • Regularly inspect and replace all clutch components showing signs of wear or excessive heat. Rekluse recommends inspecting after the first 10 hours of use, then every 20 hours after that. • Measuring the clutch pack and the EXP disk can help...

  • Page 29: 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 at: 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 30: 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. Hours: Monday thru Friday: 8:00 a.m. - 5:00 p.m. Mountain Time zone Email: tech@rekluse.com...
  • Page 31 INSTALLATION & USER’S GUIDE RadiusX Clutch for Cable Actuated Bikes and ATVs Doc ID: 191-6300B Revision: 101722 ©2021 Rekluse Motor Sports Rekluse Motor Sports, Inc. customerservice @rekluse.com...
  • Page 32 Changing the EXP Springs ..........21 BREAKING-IN THE NEW CLUTCH ........23 OPTIMIZING THE CLUTCH LEVER ......... 25 Optimization with OE Perch Adjuster ......25 Optimizing the Rekluse Adjustable Reach Lever ... 26 MAINTENANCE ..............27 Clutch Wear ..............27 Clutch Parts ..............28 Basket ................

  • Page 33: Installation Tips

    OE (Original Equipment) components with high- quality Rekluse components. • The OE friction disks and drive plates will be replaced with a Rekluse thin friction EXP clutch pack. • The OE pressure plate springs will be replaced with Rekluse springs.

  • Page 34: Tools Needed

    OEM or aftermarket wet clutch. Visit www.rekluse.com learn more. • This clutch pack is not legal to race with in the AMA Limited or Stock class. TOOLS NEEDED 10 mm Metric Torque 8 mm socket socket Wrench Wrench 4 mm...

  • Page 35: Disassembling The Clutch

    DISASSEMBLING THE CLUTCH 1. Soak the Rekluse friction disks in new oil for at least 5 minutes. Make sure the friction disks are coated on both sides. 2. If applicable, turn the fuel petcock to “OFF.” 3. For bikes, lay the bike on its left side. Catch any fluids that might drain into a suitable container.
  • Page 36 4. Remove the OE clutch cover and set it aside. It will be reused. 5. Remove the OE pressure plate bolts, springs, and pressure plate. Set them aside; they may be reused. Note: Throw-out washers can stick to the back of the pressure plate.
  • Page 37 Note: Some models have a judder spring (clutch boss spring), a spring seat, and a narrow friction located in the bottom of the OE friction pack. If your model is equipped with these parts, remove them and set the spring aside. Refer to the included Setup Sheet to determine if your model reuses any of these parts.

  • Page 38: Installing The Cluck Pack

    Notes for Clutch Pack Installation • Some OE baskets have “half slots” at the top of the basket tangs. Rekluse products require the entire clutch pack be installed into the MAIN (deeper) basket slots. Do not use the “half slots” (see below).
  • Page 39 Note: If the basket is notched or worn, Rekluse recommends replacing it with a Rekluse Billet Clutch Basket (available for most models). • Inspect your OE center hub and pressure plate flanges for excess wear. If wear is visible use a drop gauge to verify that the wear across the flange does not exceed .005”...

  • Page 40: Install Clutch Pack

    Install Clutch Pack 1. Install all of the Rekluse basket sleeves into the basket slots. Make sure the bottom of the sleeve is facing down, and the sleeve tabs sit against the inside of the basket. Sleeve tabs sit inside the...
  • Page 41 4. If your kit includes a Rekluse throw-out spacing washer, install it on top of your OE throw-out as indicated by the included Setup Sheet. Suzuki RM-Z450 Models: The needle bearing only has the bearings on one side. Make sure that the bearing side is facing the throw-out and the flat side is facing the pressure plate.
  • Page 42 5. Reinstall the pressure plate, then install the Rekluse pressure plate springs and OE bolts. Note: For Yamaha YZ250F (2019+), YZ250FX (2020+), & WR250F (2020+) when installing the pressure plate align the indent in the pressure plate with the indent in the center hub.
  • Page 43 Note: DRZ 400, KLX 400, KX 500 bike models: If your kit includes Rekluse screw sleeves or spring bolts, install them in place of the OE components. The DRZ 400 and KLX 400 models will utilize the supplied Rekluse screw sleeves and OE bolts, and KX 500 models will utilize supplied Rekluse screw sleeves and Rekluse bolts.
  • Page 44 Doc ID: 191-6300B Pg. 14 Doc Rev: 101722...

  • Page 45: Setting The Installed Gap

    If Free Play Gain is new to you, follow the instructions below. You can also view the video titled “How to Check Free Play Gain” on our website at www.rekluse.com/support/videos. Optimal Free Play Gain yields 1/8”-1/4” (3 mm-6 mm) of clutch lever movement, measured at the ball end of the lever.

  • Page 46: Two Methods To Check Free Play Gain

    Two Methods to Check Free Play Gain There are two ways to check for 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 47: The Hand Method

    c) While holding the top end of the rubber band against the handlebar, stretch the band downward, and then loop it through itself. d) Pull the band through the loop, and then attach it to the outside end of the clutch lever. e) While still in NEUTRAL, quickly rev the engine between 5,000-7,000 RPM (1/2 to ¾...
  • Page 48 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. Notice the movement in the clutch lever when the engine is revved. This is your Free Play Gain. d) When the bike/ATV returns to idle, rev the engine between 5,000-7,000 RPM a second time to verify the Free Play Gain again.

  • Page 49: Adjusting The Installed Gap

    ADJUSTING THE INSTALLED GAP After checking for Free Play Gain, you may need to adjust the installed gap. If the Free Play Gain is optimal, continue to “Breaking-In the New Clutch”. If the 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 50 Adjust the Installed Gap Solution Symptom Reason • Clutch lever moves Tighten the cable: in too far (too increase the length much Free Play of the in-line cable Gain) adjuster housing Installed gap until the correct • Clutch has is too small amount of Free Play excessive drag or Gain is achieved.

  • Page 51: Tuning The Exp

    TUNING THE EXP This kit includes multiple spring settings to adjust the engagement RPM of the EXP friction disk. The EXP friction disk comes preinstalled with the recommended “Medium” setting. See the included Setup Sheet for a chart of the available EXP spring configurations.
  • Page 52 Doc ID: 191-6300B Pg. 22 Doc Rev: 101722...

  • Page 53: Breaking-In The New Clutch

    BREAKING-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 steps for breaking in your clutch and any time new friction disks, EXP bases, Teflon pads, or wedges are installed.
  • Page 54 5. Without using the clutch lever, accelerate moderately to approximately 5,000 RPM to fully lock up the clutch and come to a complete stop. Repeat 10 times. 10 roll-on starts 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.

  • Page 55: Optimizing The Clutch Lever

    OPTIMIZING THE CLUTCH LEVER If your bike model is not equipped with a perch adjuster bolt, you may purchase, as an option, a Rekluse Adjustable Reach Lever. Optimization with OE Perch Adjuster Kits for Honda the CRF 450 and CRF 250 include a new perch adjuster bolt.

  • Page 56: Optimizing The Rekluse Adjustable Reach Lever

    Optimizing the Rekluse Adjustable Reach Lever Set the clutch lever to the desired reach point while maintaining clutch lever slack. • Turning your adjuster bolt farther in will push the lever farther from the bar and allow for a further reach point.

  • Page 57: Maintenance

    ATV and clutch. Clutch Wear Rekluse clutches are built using high quality materials but do wear based on the rider’s use, type of terrain, and natural wear and tear. To keep your clutch performing at its best, perform regular maintenance on your bike/ATV and clutch based on your riding style.

  • Page 58: Clutch Parts

    Clutch Parts • Regularly inspect and replace all clutch components showing signs of wear or excessive heat. Rekluse recommends inspecting after the first 10 hours of use, then every 20 hours after that. • Measuring the clutch pack and the EXP disk can help...

  • Page 59: 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 at: 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 60: 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. Hours: Monday thru Friday: 8:00 a.m. - 5:00 p.m. Mountain Time zone Email: tech@rekluse.com...

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