Rekluse RadiusCX Installation & User Manual Download Page 1

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Rekluse Motor Sports, Inc.

[email protected]

INSTALLATION & USER’S

GUIDE

RadiusCX Clutch

For KTM/Husqvarna DS Clutches

Doc ID: 191-7913A

Revision: 082018

Summary of Contents for RadiusCX

Page 1: ...2017 Rekluse Motor Sports Rekluse Motor Sports Inc customerservice rekluse com INSTALLATION USER S GUIDE RadiusCX Clutch For KTM Husqvarna DS Clutches Doc ID 191 7913A Revision 082018...

Page 2: ...slave cylinder 22 BLEED THE CLUTCH LINE 26 SET THE INSTALLED GAP 29 Step 1 Find the starting point 30 Step 2 Learn how to check Free Play Gain 31 Two Ways to Check for Free Play Gain 32 The Rubber Ban...

Page 3: ...isks INSTALLATION TIPS Read the safety information sheet included with your kit Protect eyes and skin wear safety glasses and thin disposable work gloves Read this entire document before performing an...

Page 4: ...e the heavier Belleville spring from KTM KTM calls it the 280 spring Replacing this spring makes the clutch engagement more aggressive However this will increase the pull on the clutch lever The part...

Page 5: ...DED PARTS Item Description Qty 27 Center hub 1 69 Steel drive plates 8 63 TorqDrive friction disks 7 16 Lining plate 1 13 EXP base 2 85 EXP wedge assembly 6 60 60 1 EXP adjustment springs colors vary...

Page 6: ...Clutch cover 1 30 Tab lock washer 1 86 Adjustable slave cylinder assembly 1 Not shown Torx head screws T 25 Torx bit included 6 Not shown Orange Free Play Gain rubber band 1 Visit www rekluse com sup...

Page 7: ...side Catch any fuel that might drain in a suitable container 3 Use an 8 mm socket to remove the clutch cover If your bike has an oil plug loosen the plug before removing the cover 4 Remove the follow...

Page 8: ...pressure plate screws 2 Spring ring 3 Belleville spring 4 Slider ring 5 Pressure plate 6 Throw out bearing and washer 7 Clutch pack 8 6 Drive pins Be careful that the drive pins do not fall into the e...

Page 9: ...h or breaker bar and a 27 mm socket 6 Remove the OE tab washer 7 Remove the OE center hub from the clutch basket while leaving the thrust washer on the main shaft NOTE Check that the thrust washer is...

Page 10: ...information Notes for Clutch Pack Installation Some friction disks are marked with a small colored dot This mark is used for processing and can be ignored Some OE basket have half slots at the top of...

Page 11: ...ll in place 3 Reinstall the new Rekluse tab washer and center clutch nut 4 Using the 27 mm socket and torque wrench torque the center clutch nut to 50 ft lb 68 N m 5 Using the channel lock pliers bend...

Page 12: ...clutch performance If you install them backwards the clutch will still function but will lack proper modulation performance 8 Align the drive pin notches in the steel drive plate with the drive pins o...

Page 13: ...drive plate install a Rekluse fiction disk 10 Continue alternating the steel drive plates with the friction disks for the entire Rekluse clutch pack There will be a total of 8 steel drive plates and...

Page 14: ...13A Doc Rev 082018 Clutch pack overview 1 Steel drive plate 2 TorqDrive friction disk 3 Alternate steel drive plates with friction disks 4 EXP disk 5 Total clutch pack 8 steel drive plates and 7 frict...

Page 15: ...URE 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...

Page 16: ...h the slots in the hub NOTE 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 wit...

Page 17: ...re 3 possible settings on the OE pressure ring Please refer to the Setup Sheet at the back of the manual for optimized pressure ring setting For a simple setting set it to setting II 4 strokes and 201...

Page 18: ...m the OE clutch cover and install it onto the new Rekluse clutch cover 10 Install the Rekluse clutch cover then lightly tightening the cover bolts in a star pattern Tighten bolts in small increments b...

Page 19: ...for the install During the bleed and assembly note that there is a small ball bearing installed in the slave piston with a small amount of grease When installing the Rekluse slave cylinder make sure t...

Page 20: ...e 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 a...

Page 21: ...d can shoot out from the slave cylinder port Be sure to wear eye protection 7 Repeat steps 3 6 until there are no air bubbles coming out in the fluid when the piston is compressed 8 When the bleeding...

Page 22: ...n performing the following steps This method retains the fluid inside the line and makes the final bleeding step easier 1 Stand the bike up and lean it on its kickstand or place it on a suitable bike...

Page 23: ...he 2 OE crush washers 5 Attach the clutch fluid line to the Rekluse slave cylinder using the OE banjo bleeder bolt and the 2 crush washers from Rekluse Make sure the clutch fluid line is between the 2...

Page 24: ...ave cylinder remove the OE slave cylinder from the engine Keep the OE bolts for reuse 8 Mount the Rekluse slave cylinder to the engine using the OE bolts NOTE Some models have a piston diaphragm seal...

Page 25: ...wing 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 NOTE If you need to install...

Page 26: ...d 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...

Page 27: ...the cap and bladder from the clutch master cylinder Adjust the reservoir so it is level with the ground 3 Top off the master cylinder with the recommended clutch fluid until it is 75 full 4 Pump the c...

Page 28: ...d port when the pressure is released from the bleed tube 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...

Page 29: ...intain your installed gap can result in premature wear or failure of your clutch The installed gap is the free space in the clutch pack when the EXP disk is disengaged collapsed The installed gap is w...

Page 30: ...ance 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...

Page 31: ...Gain The proper installed gap is verified by checking Free Play Gain Correct Free Play Gain Correct installed gap If you are familiar with checking Free Play Gain check for Free Play Gain then skip to...

Page 32: ...heck for Free Play Gain Rekluse recommends that you begin with the rubber band method first to check for Free Play Gain and then learn the hand method The Rubber Band Method Use the rubber band method...

Page 33: ...ine and let it warm up for 2 3 minutes to idle down and warm the engine oil b Stretch the included rubber band between your thumbs and then place the top end of the rubber band on the outer end of the...

Page 34: ...begin place the bike in NEUTRAL start the engine and let it warm up for 2 3 minutes to idle down and warm up the engine oil b With the bike at idle use one finger to apply pressure at the end of the...

Page 35: ...k 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...

Page 36: ...h and come to a complete stop Repeat 10 times 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 Make necessary adjustments befo...

Page 37: ...Gain and adjust the installed gap Do not perform 3rd gear starts with this product Starting in 3rd gear will burn up the clutch and decrease the performance of this product in a short amount of time...

Page 38: ...e Play Gain is achieved d Refer to the following pictures and chart in the next section for additional adjustment information e The Free Play Gain will change as the clutch pack wears over time f Chec...

Page 39: ...Clutch 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...

Page 40: ...as necessary Clutch wear is dependent on the riders use The OE spring ring can be optimized based on the wear and height of the clutch pack See the attached Setup Sheet for the spring ring optimizati...

Page 41: ...ttached Setup Sheet or if the disks are glazed and or burnt Replace the drive plates if they show signs of excessive heat Disk inspection examples When inspecting the clutch pack the following picture...

Page 42: ...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 we...

Page 43: ...oil can make the clutch more likely to squeal or chatter EXP TUNING OPTIONS Adjusting the engine idle speed to match your engagement setting is important and greatly affects the overall feel of how t...

Page 44: ...iver 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 ENGAGEMENT SETTING 250 350 L...

Page 45: ...e pin The pin should sit almost flush with the EXP base 6 Flip the EXP friction disk over and repeat on the other side depending on engagement preference 7 If you need to disassemble the EXP disk you...

Page 46: ...the EXP is reassembled Operating the clutch without the pads in place will cause part damage or failure BUMP STARTING If your bike needs to be bump started due to a dead battery or any other reason fo...

Page 47: ...6 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...

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