Rekluse RADIUS CX Installation & User Manual Download Page 7 | Manualshive

Page: 7 / 39

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Doc ID: 191-7911A

Doc Rev: 080420

Pg. 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.

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Summary of Contents for RADIUS CX

Page 1: ... 2017 Rekluse Motor Sports Rekluse Motor Sports Inc support rekluse com INSTALLATION USER S GUIDE RadiusCX Clutch Upgrade Kit For KTM Husqvarna DDS clutches Doc ID 191 7911A Revision 080420 ...

Page 2: ... Find the starting point 16 Step 2 Learn how to check Free Play Gain 17 Two Ways to Check for Free Play Gain 19 The Rubber Band Method 19 The Hand Method 22 Step 3 Break in the new clutch 24 Step 4 Adjust the installed gap and Recheck Free Play Gain 26 FREE PLAY GAIN ADJUSTMENTS 28 MAINTENANCE 29 Disk inspection examples 31 TROUBLESHOOTING 32 Performance issues 32 Clutch noise 32 EXP TUNING OPTION...

Page 3: ...fore performing any steps Lay the bike on its left side when replacing the clutch This makes the clutch work easier and eliminates the need to drain the oil 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 Rekluse Factory Formulated Oil is a perfect co...

Page 4: ...the 280 spring Replacing this spring makes the clutch engagement more aggressive However this will increase the pull on the clutch lever The spring comes stock on 2013 and newer Factory Edition 450SX F bikes 2014 and newer 450SX F XC F bikes 2017 and newer 450 500 EXC F bikes The part number is KTM Part 78932005000 TOOLS 4 mm Allen Wrench 8 mm Socket Torque Wrench T 25 Torx Bit Oil Calipers Fluid ...

Page 5: ...c ID 191 7911A Doc Rev 080420 Pg 5 INCLUDED PARTS Visit www rekluse com support for a full parts fiche illustration and part numbers Item Description Qty 63 TEC Steel Drive Plate 9 69 TorqDrive Friction 8 ...

Page 6: ...n in a suitable container 3 Use an 8 mm socket to remove the clutch cover 4 Use a T 25 Torx bit to remove the following parts When removing the Bellville spring make sure to note the orientation of the spring See the following picture for reference 6 pressure plate screws Pressure ring Belleville spring Slider ring Lining plate Core EXP 3 0 pressure plate Clutch pack ...

Page 7: ...Doc ID 191 7911A Doc Rev 080420 Pg 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 ...

Page 8: ...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 CLUTCH PACK INSTALLATION Each clutch pack comes with a set of steel plates a set of friction disks and an EXP disk The clutch pull effort has different pressure ring settings that depend on the thickness of the clutch pack You will need to measure t...

Page 9: ...n 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 3 Place the steel plates in the orientation shown with the shark fin notches facing to the right All drive plates will follow this orientation Drive pin notches Drive pins Shark fin notches ...

Page 10: ... steel drive plate Some friction disks are marked with a small colored dot This mark is used for processing and can be ignored 5 Continue alternating the steel drive plates with the friction disks for the entire Rekluse clutch pack 6 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 Refer to the Setup Sheet located at the...

Page 11: ... throw out and thrust washer are still on the main shaft and not stuck to the bottom of the center hub assembly Missing the thrust washer will cause clutch performance issues 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 pressure plate b...

Page 12: ...he hub When the pressure plate is seated correctly the threaded standoffs will come through the openings of the pressure plate 4 Place the OE slider ring on the pressure plate with the top marking facing up The top side is rounded and the bottom edge is sharp 5 Place the OE Belleville spring onto the slider ring with the rounded dome side facing up ...

Page 13: ...etup Sheet located at the back of the manual For a simple setting set it to setting II 4 strokes and 2017 2 strokes or Y pre 2017 2 strokes 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 Incorrect The Belleville spring is upside down...

Page 14: ...all it onto the new Rekluse clutch cover 9 Install the Rekluse clutch cover by lightly tighten the cover bolts in a star pattern 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 ...

Page 15: ...e installed gap is the free space in the clutch pack when the EXP disk is disengaged collapsed This gap allows the clutch to spin freely until the engagement RPM is reached and the EXP disk expands to close the gap and apply pressure to the pressure plate which in turn drives the motorcycle forward The installed gap is what allows the auto function of the product to perform properly Use the follow...

Page 16: ...kwise until it stops under light pressure This is your starting point The resistance you feel is where the throw out begins to lift the pressure plate Finding the right starting point may take a few tries but you will feel a noticeable change in turning effort once you reach that point Stop when you feel the pressure increase The starting point will change as the clutch pack wears overtime c Once ...

Page 17: ...e Free Play Gain If you are familiar with Free Play Gain you can skip to Step 3 Break in the new clutch If Free Play Gain is new to you follow the instructions below to help you learn this important step You can also view the video entitled How to Check Free Play Gain on our website at www rekluse com support videos Free Play Gain is different from the normal free play you are used to with your st...

Page 18: ...all The bike may drag and stall because it has difficulty disengaging the clutch It may also be difficult to shift Too much Free Play Gain will not hurt the clutch but it will negatively affect clutch performance With too little or no Free Play Gain the installed gap is too large This means when the EXP is fully expanded it does not lift the pressure plate The clutch may slip and make the bike see...

Page 19: ...Rubber Band Method Use the rubber band method for the initial set up It can also be used before each ride until you feel comfortable checking the Free Play Gain using the hand method BEFORE YOU BEGIN verify that the bike is in NEUTRAL before checking 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 y...

Page 20: ...e 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: ... 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 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 It is very important the motor returns to idle before revving the engine again or Free Play Gain will not be correct ...

Page 22: ...TRAL before checking 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 Motorcycles equipped with a Rekluse auto clutch can move suddenly and unexpectedly and cause riders to lose control To a...

Page 23: ... continue to apply light pressure and quickly rev the engine between 5 000 7 000 RPM 1 2 to 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 returns to idle rev the engine between 5 000 7 000 RPM a second time to feel the Free Play Gain again e Continue with Step 3 to break in the new clutch ...

Page 24: ... 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 Failure to follow the break in procedure and oil screen inspection process could cause motor oil delivery failure which can result in motor failure serious injury or death Break in Procedure Number of times Rev Cycles 1 Place the ...

Page 25: ...ing 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 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 10 roll on starts 6 Without using the clutch lever start in 2nd gear then accel...

Page 26: ...th this product Starting in 3rd gear will burn up the clutch and decrease the performance of this product in a short amount of time Step 4 Adjust the installed gap and Recheck Free Play Gain Once you have learned how to check Free Play Gain you need to finish adjusting the installed gap then recheck the Free Play Gain until the clutch lever moves only 1 8 3 mm The gap is adjusted by turning the sl...

Page 27: ...chart in the next section for additional adjustment information e The Free Play Gain will change as the clutch pack wears over time f Checking the Free Play Gain is easy and indicates when the install gap needs adjusting 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 ...

Page 28: ...tch has excessive drag or stalls It is difficult to fully override the clutch with the lever Installed gap is too small Turn the adjuster screw clockwise 1 2 marks to increase the installed gap and decrease Free Play Gain Recheck Free Play Gain Clutch lever only moves slightly or does not move at all too little Free Play Gain Clutch slips Bike seems to lose power Installed gap is too large Turn th...

Page 29: ...r or excessive heat and replace components as necessary Clutch wear is dependent on the riders use Maintenance Protocol Maintenance Intervals Check and verify Free Play Gain Every ride Inspect all clutch parts for excessive wear or heat Replace as needed Refer to OE service manual The OE spring ring can be optimized based on the wear and height of the clutch pack See the Setup Sheet Setup Sheet lo...

Page 30: ...efore every ride and adjust if necessary Repeat the break in procedure anytime you replace the EXP bases Teflon pads EXP wedges or frictions disks Always soak friction disks or EXP bases in oil for at least 5 minutes before installing Replace friction disks if they measure below specifications listed on the attached Setup Sheet or if the disks are glazed and or burnt Replace the drive plates if th...

Page 31: ...ive plate teeth See pictures below Not all drive plates look the same and may look different than pictured Normal Heat High Heat Excessive Heat Blue Black Friction Disks Due to the dark color of the friction material the friction disks will appear almost black as soon as they are put in oil During inspection look for glazing of the friction material Glazing will appear shiny and feel like glass ev...

Page 32: ... or chatter coming from the clutch at low RPM as it engages Clutch squeal is caused by the clutch components vibrating as the clutch engages and can become more audible as the clutch gets hot Adjusting the installed gap will NOT affect clutch squeal or chatter For bike models that have clutch squeal or chatter here are some recommendations to reduce or eliminate it Change the oil For optimal clutc...

Page 33: ...etting from Rekluse Use the following steps to change the springs It is NOT necessary to disassemble the EXP halves to change springs Changing the springs 1 Using a flat blade screwdriver push the turn pin in far enough to clear the opposite side of the EXP to unlock the pin 2 With the pin still pushed past the base turn 90 to remove the pin and spring 3 Remove the remaining 2 pins and springs fro...

Page 34: ...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 If you disassemble the EXP the Teflon pads may fall out or be stuck to the ramp surfaces of the EXP bases Take care to ensure all pads are correctly placed in...

Page 35: ...le slave cylinder counterclockwise to collapse the gap until no resistance is felt 2 Bump start the bike The clutch will function like a manual clutch at this point but the clutch will not be fully over rideable at high RPMs 3 Once the bike is started readjust the installed gap ENGAGEMENT SETTING SPRING CONFIGURATION 450 500 501 4 stroke 250 300 2 stroke Pre 2017 250 300 2 stroke 2017 250 350 EXC ...

Page 36: ...ons related to product installation tuning and performance 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 5 00 p m Thursday 8 00 a m 4 3...

Page 37: ...ive plates will also show signs of bluing or darkness Squeal Chirping noise under acceleration or take off Chatter Shutter Vibration or surge under acceleration as the clutch engages Drag When stopped or idling in gear the bike will try pulling or on a stand the wheel will spin Chain Slap Drag at idle in gear causing the chain to slap noisily against the swing arm Low RPM Slip Considered engagemen...

Page 38: ...e or OEM disks recommended Tall Bike gearing Replace wedges with a heavier set if the gearing is taller than stock High RPM slip No Free Play Gain Re adjust the installed gap and re check Free Play Gain Modified motor If running Core EXP Replace the pressure plate springs with a heavier set if highly modified If running EXP upgrading to Core EXP is recommended Pressure plate springs Be sure the Re...

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