Rekluse RadiusX Clutch Installation & User Manual Download Page 2

Page: 2 / 61

Pg. 2

Doc ID: 191-6300B

Doc Rev: 101722

TABLE OF CONTENTS

OVERVIEW ......................................................................... 2

INSTALLATION TIPS .......................................................... 3

TOOLS NEEDED ................................................................. 4

INCLUDED PARTS ............................................................. 4

DISASSEMBLING THE CLUTCH ....................................... 5

INSTALLING THE CLUCK PACK ....................................... 8

Notes for Clutch Pack Installation .................................... 8

Install Clutch Pack .......................................................... 10

SETTING THE INSTALLED GAP ...................................... 15

CHECKING FREE PLAY GAIN ......................................... 15

Learning How to Check the Free Play Gain .................. 15

Two Methods to Check Free Play Gain ......................... 16

The Rubber Band Method .............................................. 16

The Hand Method .......................................................... 17

ADJUSTING THE INSTALLED GAP ................................. 19

TUNING THE EXP ............................................................. 21

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 ............................................................................ 28

Disk Inspection Examples .............................................. 29

NEED ADDITIONAL HELP? .............................................. 30

OVERVIEW

Summary of Contents for RadiusX Clutch

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

Page 2: ...GAIN 15 Learning How to Check the Free Play Gain 15 Two Methods to Check Free Play Gain 16 The Rubber Band Method 16 The Hand Method 17 ADJUSTING THE INSTALLED GAP 19 TUNING THE EXP 21 Changing the E...

Page 3: ...ct for a customer or another person instruct them to read the Safety Information document and the Installation and User Guide before operating the vehicle with the product Protect your eyes and skin w...

Page 4: ...lass TOOLS NEEDED INCLUDED PARTS The parts included in the kit depend on the bike or ATV model See the included sheet Setup Sheet for a list of included parts and diagram You can also visit our websit...

Page 5: ...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...

Page 6: ...ide 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 Be sure to re...

Page 7: ...ing 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 in...

Page 8: ...use the half slots see below Inspect the clutch basket for damper and or spring play Inspect the clutch basket for notching Do not install sleeves or use this product with a notched basket Notched bas...

Page 9: ...let 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...

Page 10: ...ted in the basket the sleeve tops may sit slightly above or below the top of the basket 2 If the included Setup Sheet indicates your bike or ATV reuses the judder spring reinstall only the judder spri...

Page 11: ...n 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 a...

Page 12: ...sure 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 w...

Page 13: ...ifferent pressure plate spring colors install them in an alternating pattern This will ensure an even force is applied to the pressure plate and clutch 6 Tighten the pressure plate bolts in a star pat...

Page 14: ...Pg 14 Doc ID 191 6300B Doc Rev 101722...

Page 15: ...CRUCIAL Failure to properly maintain the installed gap can result in premature wear or failure of the clutch Failure to check and verify Free Play Gain can cause failure or damage to this product Set...

Page 16: ...may result in the bike or vehicle lurching forward and loss of control and or injury may result A Rekluse auto clutch can make your motorcycle or vehicle appear to be in neutral when in gear even when...

Page 17: ...he engine is revved This is your Free Play Gain Note It is very important the motor returns to idle before revving the engine again or the Free Play Gain will not be correct f When the bike ATV return...

Page 18: ...kly 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 ATV...

Page 19: ...he installed gap needs to be adjusted The installed gap should be fine tuned in small increments and then recheck Free Play Gain Refer to the table below to set the proper installed gap based on your...

Page 20: ...Tighten the cable increase the length of the in line cable adjuster housing until the correct amount of Free Play Gain is achieved Recheck Free Play Gain Clutch lever only moves slightly or does not...

Page 21: ...moves forward while in gear with the throttle closed However with a small opening of the throttle the bike should move forward Changing the EXP Springs 1 Using a flathead screwdriver push the turn pi...

Page 22: ...Pg 22 Doc ID 191 6300B Doc Rev 101722...

Page 23: ...tor oil delivery failure which can result in motor failure serious injury or death Break in Procedure Number of times Rev Cycles 1 Place the bike or ATV in NEUTRAL 2 With your hand off the clutch leve...

Page 24: ...approximately 5 000 RPM and come to a complete stop Repeat 10 times 10 roll on starts 7 Place the bike or ATV in NEUTRAL and recheck Free Play Gain 8 Continue to step 4 to adjust the installed gap unt...

Page 25: ...hese bolts will not be used on the CRF450RX Kits for Yamaha the YZ450F and YZ250F include a new perch adjuster bolt Replace your OE perch adjuster bolt with the one included in your kit These bolts wi...

Page 26: ...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 Backing your a...

Page 27: ...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 Maintai...

Page 28: ...larly change the oil as per the bike ATV manufacturer s recommendations Clutch performance and longevity depend on oil quality Oil recommendations can also be viewed under Tech Tips on our website at...

Page 29: ...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 frict...

Page 30: ...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...

Page 31: ...2021 Rekluse Motor Sports Rekluse Motor Sports Inc customerservice rekluse com INSTALLATION USER S GUIDE RadiusX Clutch for Cable Actuated Bikes and ATVs Doc ID 191 6300B Revision 101722...

Page 32: ...GAIN 15 Learning How to Check the Free Play Gain 15 Two Methods to Check Free Play Gain 16 The Rubber Band Method 16 The Hand Method 17 ADJUSTING THE INSTALLED GAP 19 TUNING THE EXP 21 Changing the E...

Page 33: ...ct for a customer or another person instruct them to read the Safety Information document and the Installation and User Guide before operating the vehicle with the product Protect your eyes and skin w...

Page 34: ...lass TOOLS NEEDED INCLUDED PARTS The parts included in the kit depend on the bike or ATV model See the included sheet Setup Sheet for a list of included parts and diagram You can also visit our websit...

Page 35: ...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...

Page 36: ...ide 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 Be sure to re...

Page 37: ...ing 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 in...

Page 38: ...use the half slots see below Inspect the clutch basket for damper and or spring play Inspect the clutch basket for notching Do not install sleeves or use this product with a notched basket Notched bas...

Page 39: ...let 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...

Page 40: ...ted in the basket the sleeve tops may sit slightly above or below the top of the basket 2 If the included Setup Sheet indicates your bike or ATV reuses the judder spring reinstall only the judder spri...

Page 41: ...n 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 a...

Page 42: ...sure 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 w...

Page 43: ...ifferent pressure plate spring colors install them in an alternating pattern This will ensure an even force is applied to the pressure plate and clutch 6 Tighten the pressure plate bolts in a star pat...

Page 44: ...Pg 14 Doc ID 191 6300B Doc Rev 101722...

Page 45: ...CRUCIAL Failure to properly maintain the installed gap can result in premature wear or failure of the clutch Failure to check and verify Free Play Gain can cause failure or damage to this product Set...

Page 46: ...may result in the bike or vehicle lurching forward and loss of control and or injury may result A Rekluse auto clutch can make your motorcycle or vehicle appear to be in neutral when in gear even when...

Page 47: ...he engine is revved This is your Free Play Gain Note It is very important the motor returns to idle before revving the engine again or the Free Play Gain will not be correct f When the bike ATV return...

Page 48: ...kly 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 ATV...

Page 49: ...he installed gap needs to be adjusted The installed gap should be fine tuned in small increments and then recheck Free Play Gain Refer to the table below to set the proper installed gap based on your...

Page 50: ...Tighten the cable increase the length of the in line cable adjuster housing until the correct amount of Free Play Gain is achieved Recheck Free Play Gain Clutch lever only moves slightly or does not...

Page 51: ...moves forward while in gear with the throttle closed However with a small opening of the throttle the bike should move forward Changing the EXP Springs 1 Using a flathead screwdriver push the turn pi...

Page 52: ...Pg 22 Doc ID 191 6300B Doc Rev 101722...

Page 53: ...tor oil delivery failure which can result in motor failure serious injury or death Break in Procedure Number of times Rev Cycles 1 Place the bike or ATV in NEUTRAL 2 With your hand off the clutch leve...

Page 54: ...approximately 5 000 RPM and come to a complete stop Repeat 10 times 10 roll on starts 7 Place the bike or ATV in NEUTRAL and recheck Free Play Gain 8 Continue to step 4 to adjust the installed gap unt...

Page 55: ...hese bolts will not be used on the CRF450RX Kits for Yamaha the YZ450F and YZ250F include a new perch adjuster bolt Replace your OE perch adjuster bolt with the one included in your kit These bolts wi...

Page 56: ...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 Backing your a...

Page 57: ...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 Maintai...

Page 58: ...larly change the oil as per the bike ATV manufacturer s recommendations Clutch performance and longevity depend on oil quality Oil recommendations can also be viewed under Tech Tips on our website at...

Page 59: ...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 frict...

Page 60: ...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...

Page 61: ...P TUNING OPTIONS HEAVY WEDGES ARE AVAILABLE SEPARATELY FROM REKLUSE ITEM NO PART QTY 1 BASKET SLEEVES 12 2 FRICTION DISK TORQDRIVE 8 3 OEM PRESSURE PLATE 2 4 REKLUSE SPRINGS 6 5 OEM SPRING BOLTS 6 6 G...

Search results

Summary of Contents for RadiusX Clutch

Reviews:

Related manuals for RadiusX Clutch

Brands by name

Popular brands

Rekluse RadiusX Clutch, Installation & User Manual

Search results

Summary of Contents for RadiusX Clutch

Reviews:

Related manuals for RadiusX Clutch

Brands by name

Popular brands