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Rekluse Motor Sports, Inc.

[email protected]

INSTALLATION GUIDE

For Harley-Davidson Big Twin

Cable Actuated

Doc ID: 191-6203A

Revision: 100219

Содержание RADIUSX

Страница 1: ...2015 Rekluse Motor Sports Rekluse Motor Sports Inc customerservice rekluse com INSTALLATION GUIDE For Harley Davidson Big Twin Cable Actuated Doc ID 191 6203A Revision 100219...

Страница 2: ...how to check Free Play Gain 19 Two Ways to Check for Free Play Gain 21 The Rubber Band Method 21 The Hand Method 23 ADJUST THE INSTALLED GAP 25 BREAK IN THE NEW CLUTCH 26 EXP TUNING OPTIONS 28 Changin...

Страница 3: ...nline at www rekluse com support videos Protect eyes and skin wear safety glasses and work gloves Work in a well ventilated area Use the torque values listed in the instructions Otherwise use the torq...

Страница 4: ...djustment springs colors vary 15 31 Spring ring hold down plate 1 63 Steel drive plate 040 1 mm thick 9 68 Steel drive plate 065 1 6 mm thick 1 69 1 TorqDrive friction disks 9 69 2 Damper judder sprin...

Страница 5: ...id not provide enough torque capacity alternate springs can be purchased to optimize the clutch setup Clutch Torque Capacity Max Engine Output Torque ft lb Harley Davidson Spring Part Number Spring Ty...

Страница 6: ...gnificantly improve clutch life and performance by reducing this heat DISASSEMBLE CLUTCH 1 Make sure the bike has cooled before disassembling the clutch 2 Soak the EXP disk and TorqDrive friction disk...

Страница 7: ...oil drain plug then drain the oil 5 Remove any parts that are attached or blocking the primary chaincase cover These may include the left floorboard foot peg s shift lever and or the side stand Note B...

Страница 8: ...following OE parts 1 Pressure plate bolts 2 Spring ring 3 Belleville spring 4 Pressure plate 5 Clutch pack 6 Damper judder spring and seat Note Set aside the OE damper judder spring damper seat and B...

Страница 9: ...ll colored dot This mark is used for processing and can be ignored Clutch pack 1 Inspect the clutch basket for notching Do not install sleeves or use product with a notched basket Notched basket tang...

Страница 10: ...s the sleeves will fit deeper into the basket than others This is normal 3 Install the Rekluse damper judder spring fiction disk 150 3 81 mm into the clutch basket 4 Reinstall the damper judder seat a...

Страница 11: ...all the EXP disk on top of the last steel drive plate Align the notches on the EXP disk with the notches on the friction disks Note If your bike s idle RPM has changed from stock meaning that it idles...

Страница 12: ...ESSURE PLATE 1 Fully collapse the in line cable adjuster so that the cable slack makes the clutch lever very sloppy at the perch Note Adding cable slack ensures that the cable will not have excessive...

Страница 13: ...juster still installed You will reuse this whole assembly including the push rod and jam nut 3 Remove the throw out adjuster jam nut from the center of the pressure plate using an 11 16 socket 4 Insta...

Страница 14: ...4 Doc ID 191 6203A Doc Rev 100219 5 Using a 10 mm socket torque the pressure plate bolts in a star pattern to 90 110 in lbs 10 12 4 N m OE Belleville spring OE pressure plate bolts Rekluse spring ring...

Страница 15: ...t ride your bike without adjusting the installed gap You will not be able to disengage the clutch until you set the installed gap 1 Use the long end of a hex key to turn the adjuster screw COUNTERCLOC...

Страница 16: ...uges 4 Once the installed gap is set reinstall and tighten the adjuster jam nut Use a hex key to hold the adjuster screw while using an 11 16 wrench to tighten the nut The hex key will prevent the adj...

Страница 17: ...ue the cover bolts to 84 108 in lbs 9 5 12 2 N m 4 Reinstall the drain bolt then torque the drain bolt to 36 60 in lbs 4 6 8 N m 5 With the primary cover installed use a T 27 Torx bit to remove the de...

Страница 18: ...lutch cable before it starts actuating the clutch Applying a light finger pressure will take up this slack 1 Expand the in line adjuster until the cable slack is between 1 16 and 1 8 at the lever perc...

Страница 19: ...re or damage to this product Setting the correct installed gap is critical for clutch performance Learn how to check Free Play Gain If you are familiar with checking Free Play Gain check for Free Play...

Страница 20: ...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 o This means when the EXP is fully exp...

Страница 21: ...at you begin with the rubber band method first to check for Free Play Gain and then learn the hand method The rubber band will help you learn how to recognize Free Play Gain until you are comfortable...

Страница 22: ...warm up for 2 3 minutes to idle down and warm the engine oil b Stretch the included rubber band between your thumbs then place the top end of the rubber band on the outer end of the left handlebar gr...

Страница 23: ...0 RPM so you can observe the movement while feeling for Free Play Gain with your hand The Hand Method Use the hand method to check Free Play Gain before the start of every ride for optimum performance...

Страница 24: ...191 6203A Doc Rev 100219 clutch lever when the engine is revved This is your Free Play Gain d When the bike returns to idle rev the engine between 3 000 5 000 RPM a second time to verify the Free Pla...

Страница 25: ...installed gap based on your Free Play Gain Symptom Reason Solution Too much Free Play Gain Clutch lever moves in too far Clutch has excessive drag or stalls It is difficult to fully override the clut...

Страница 26: ...ocedure Number of times 1 Warm up the bike for 2 3 minutes With the bike in NEUTRAL and your hand off of the clutch lever rev the engine 10 times being sure to let it return to idle between each rev c...

Страница 27: ...ust the installed gap Note Your clutch pack will expand with heat so final adjustment to Free Play Gain should be made when the bike is warm Remember not to ride without sufficient Free Play Gain Do n...

Страница 28: ...the EXP disk by changing the spring configuration The EXP disk comes set with the recommended Medium setting from Rekluse based on an idle of RPM 850 1050 If your idle is higher than 1050 RPM it may...

Страница 29: ...pring 3 Remove the remaining 2 pins and springs from the same side of the EXP base 4 Drop a new spring into the spring slot on the base then add the turn pin NOTE Lining up the slot in the pin with th...

Страница 30: ...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 t...

Страница 31: ...ike Refer to the Safety Information sheet for more information 1 Pull the lever tight against the handlebar 2 Wrap the Velcro safety strap around the lever and handlebar pull it tight then fasten it N...

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