Rekluse Motor Sports Radius CX Clutch User manual

©2017 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[e-mail]
INSTALLATION & USER’S GUIDE
RadiusCX Clutch
For KTM/Husqvarna DDS clutches
Doc ID: 191-7905A
Revision: 081717

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TABLE OF CONTENTS
OVERVIEW.....................................................................................3
INSTALLATION TIPS......................................................................3
Tuning Note..................................................................................4
TOOLS NEEDED............................................................................5
INCLUDED PARTS.........................................................................6
DISASSEMBLE THE CLUTCH .......................................................7
INSPECT THE DAMPERS..............................................................9
INSTALL HUBS.............................................................................10
CLUTCH PACK INSTALLATION...................................................12
PRESSURE PLATE INSTALLATION............................................17
SLAVE CYLINDER INSTALLATION.............................................22
Step 1: Bleed the new slave cylinder..........................................22
Step 2: Replace OE slave cylinder.............................................25
SET THE INSTALLED GAP AND VERIFY BY CHECKING FREE
PLAY GAIN ...................................................................................32
Step 1: Find the starting point.....................................................33
Step 2: Learn how to check Free Play Gain...............................34
Two Ways to Check for Free Play Gain .....................................36
The Rubber Band Method..........................................................36
The Hand Method.......................................................................39
Step 3: Break-in the new clutch..................................................41
Step 4: Adjust the installed gap and Recheck Free Play Gain ...43
FREE PLAY GAIN ADJUSTMENTS .............................................45
MAINTENANCE............................................................................46
Disk inspection examples...........................................................48
TROUBLESHOOTING ..................................................................49
Performance issues....................................................................49
Clutch noise................................................................................49
EXP TUNING OPTIONS ...............................................................49
Changing the springs .................................................................50
Configuration chart.....................................................................52

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BUMP-STARTING.........................................................................52
NEED ADDITIONAL HELP? .........................................................53
OVERVIEW
This kit replaces many of the OE (Original Equipment) clutch parts
while reusing some of the OE clutch parts. The following is a
summary of what is replaced and what is reused:
•The OE center clutch hub and OE pressure plate. The OE
clutch is replaced with high-quality billet components. These
parts are designed specifically for your motorcycle to ensure
optimal performance.
•All OE steel drive plates will be replaced with Rekluse TEC
drive plates
•All OE friction disks will be replaced with Rekluse TorqDrive®
disks
•All 6 of the OE drive pins will be reinstalled
•The OE clutch cover O-ring will be reused
INSTALLATION TIPS
•Read the safety information sheet
included with your kit.
•If you install this product for a customer or
another person, instruct them to read the Safety Information
document and the Installation and User Guide before operating
the bike with the product.
•Watch the “RadiusCX Auto Clutch Installation Video” by visiting
www.rekluse.com/support/videos.
•Protect eyes and skin – wear safety glasses and thin
disposable work gloves.
•Read this entire document before performing any steps.
•Lay the motorcycle on its left side when replacing the clutch.
This makes the clutch work easier and eliminates the need to
drain the oil.

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•Use an air or electric impact wrench to remove the center
clutch nut. If one is not available, you can place the bike in top
gear and hold the rear brake while loosening the center clutch
nut with a socket and breaker bar.
•Channel-lock pliers work best to bend the tabs of the washer
up over the center clutch nut.
•Use clean, quality JASO-MA or JASO-MA2 certified
transmission oil for best performance.
•Motorcycles with taller gearing or modified engines with
increased horsepower may require heavier wedges. These can
be purchased separately from Rekluse.
Tuning Note:(especially for 2-stroke owners):
•Once installed, if you desire your clutch to engage more
aggressively, one option is to purchase 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 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

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TOOLS NEEDED
4 mm Allen Wrench 5 mm Allen Wrench 8 mm Socket 27 mm Socket
T-25 Torx Bit Torque Wrench Fluid Catch
Container Channel-lock Pliers
Oil Recommended
Clutch Fluid
4mm
5 mm
8 mm
27 mm

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INCLUDED PARTS
Visit www.rekluse.com/support for
a full parts fiche illustration and part numbers.

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DISASSEMBLE THE CLUTCH
1. Turn the fuel petcock to “OFF” if applicable.
2. Lay the bike on its left 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. Use an 8 mm socket to remove the following OE parts. When
removing the Bellville spring, make sure to note the orientation
of the spring. See following picture for reference.
•6 pressure plate screws
•Pressure ring
•Belleville spring
•Slider ring
•Pressure plate
•Throw-out bearing and washer
•Clutch pack
•6 drive pins
•Center clutch nut and washer
(Removed in step 5)

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Be careful that the drive pins do not fall into the engine while
disassembling.
5. Use a hammer and large screwdriver to bend down the tabs of
the washer tab, then remove the center clutch nut with an impact
wrench or breaker bar, and a 27 mm socket.

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6.Remove the tab washer.
7.Remove the center hub assembly from the steel basket while
leaving the thrust washer on the main shaft.
Check that the thrust washer is 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.
INSPECT THE DAMPERS
The OE dampers inside the center hub assembly shrink due to heat
and use. Any movement between the dampers will shorten the life
of your clutch. Inspect the dampers before proceeding and replace
if necessary. Use the following instructions to inspect the dampers.
1. Hold the center hub assembly in your hands, then place your
thumbs on the inner hub by the embossed part numbers.

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2. Rotate the inner 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.
INSTALL HUBS
1. Remove the 6 rubber dampers from the OE center hub
assembly.
For 450SX-F/XC-F models, replace the OE inner hub with the
supplied inner hub.