Rekluse Motor Sports RadiusCX Clutch Operation manual

©2017 Rekluse Motor Sports
Rekluse
Motor Sports, Inc.
[e-mail]
I
NSTALLATION & USER’S GUIDE
RadiusCX Clutch
For KTM/Husqvarna CSS clutches
Doc ID: 191-7902A
Revision: 040919

Pg.
2 Doc ID: 191-7902A
Doc Rev: 040919
TABLE OF CONTENTS
OVERVIEW ............................................................................................... 3
INSTALLATION TIPS ................................................................................ 3
TOOLS NEEDED ...................................................................................... 4
INCLUDED PARTS ................................................................................... 5
DISASSEMBLE THE CLUTCH ................................................................. 6
INSTALL THE HUB ................................................................................... 8
CLUTCH PACK INSTALLATION............................................................... 9
PRESSURE PLATE INSTALLATION ...................................................... 14
SLAVE CYLINDER INSTALLATION ....................................................... 17
Step 1: Bleed the new slave cylinder ......................................... 17
Step 2: Replace OE slave cylinder ............................................ 20
BLEED THE CLUTCH LINE .................................................................... 24
SET THE INSTALLED GAP AND VERIFY BY CHECKING FREE PLAY
GAIN........................................................................................................ 27
Step 1: Find the starting point .................................................... 28
Step 2: Learn how to check Free Play Gain .............................. 29
Two Ways to Check for Free Play Gain..................................... 31
The Rubber Band Method ......................................................... 31
The Hand Method ...................................................................... 34
Step 3: Break-in the new clutch ................................................. 36
Step 4: Adjust the installed gap and Recheck Free Play Gain... 38
FREE PLAY GAIN ADJUSTMENTS ....................................................... 40
MAINTENANCE ...................................................................................... 41
Disk inspection examples .......................................................... 43
TROUBLESHOOTING ............................................................................ 44
Performance issues ................................................................... 44
Clutch noise ............................................................................... 44
EXP TUNING OPTIONS ......................................................................... 44
Changing the springs................................................................. 45
Configuration chart .................................................................... 47
BUMP-STARTING ................................................................................... 47
NEED ADDITIONAL HELP?.................................................................... 48

Doc ID: 191-7902A
Doc Rev: 040919
Pg. 3
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:
·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
·Read the safety information sheet
included with your kit.
·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.
·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.
·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 complement to any OEM or aftermarket wet clutch. Visit
www.rekluse.com to learn more.
OVERVIEW
INSTALLATION TIPS

Pg.
4 Doc ID: 191-7902A
Doc Rev: 040919
·Bikes with taller gearing or modified engines with increased
horsepower may require heavier wedges. These can be
purchased separately from Rekluse.
4 mm Allen Wrench
5 mm Allen Wrench
8 mm Socket
27
mm Socket
Torque Wrench
Channel
-
lock Pliers
Fluid Catch Container
No Tools
Required
Recommended
Clutch Fluid
Calipers
TOOLS NEEDED
4mm
5 mm
8 mm
27 mm

Doc ID: 191-7902A
Doc Rev: 040919
Pg. 5
*depending on bike model
Visit www.rekluse.com/support for a full parts fiche illustration and part numbers.
INCLUDED PARTS
Item
Description
Qty.
5
Pressure Plate
1
13
EXP Bases
2
16
Steel Lining Plate
1
23
Clutch Cover
1
27
Center Hub
1
30
Lock Tab Washer
1
51
Fastener - 1/4-Turn Pin
6
60.X
EXP Adjustment Spring (extra adjustment
springs are included, see last page for EXP
tuning options)
6
63
Steel Drive Plate
8 or 9*
69
TorqDrive®Friction
7 or 8*
85
Wedge Assembly
6
86
Adjustable Slave Cylinder Assembly (bleed
syringe included)
1
88
Spring Kit
1

Pg.
6 Doc ID: 191-7902A
Doc Rev: 040919
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.
DISASSEMBLE THE CLUTCH
8 mm

Doc ID: 191-7902A
Doc Rev: 040919
Pg. 7
4. Use an 8 mm socket to remove the following OE parts.
See following picture for reference.
·6 pressure plate bolts and
springs
·Pressure plate
·Throw-out bearing and
washer
·Center clutch nut and washer
·
12
drive pins
·
Clutch pack
·
Center clutch hub
Be careful that the drive pins do not fall into the engine while
disassembling.
8 mm

Pg.
8 Doc ID: 191-7902A
Doc Rev: 040919
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.
6.Remove the tab washer, then remove the hub.
1. Install the new Rekluse center clutch hub into the bike. Check to
make sure the thrust washer is still on the main shaft before you
install the hub.
2. Reinstall the Rekluse tab washer and OE center clutch nut.
3. Using the 27 mm socket and torque wrench,
torque the center clutch nut to 50 ft-lbs (68 N-m).
INSTALL THE HUB
27 mm
27 mm
Torque Wrench

Doc ID: 191-7902A
Doc Rev: 040919
Pg. 9
4. Bend up both tabs of the tab washer using channel-lock pliers.
5. Seat the 6 OE drive pins into the Rekluse outer hub.
Each clutch pack comes with a set of steel plates, a set of friction
disks, and an EXP disk. The specifics of the clutch pack depend on
the bike. The height of the assembled clutch pack and specific
information for each bike can be found on the Setup Sheet.
CLUTCH PACK INSTALLATION
Channel-lock
Pliers

Pg.
10 Doc ID: 191-7902A
Doc Rev: 040919
1. Soak the friction disks and EXP disk in new oil for at
least 5 minutes. Make sure the EXP and friction disks
are coated on both sides.
2. Install a steel drive plate first. Hold a TEC drive plate so that
the “shark fin” notches face toward the right. All the drive
plates will follow this orientation.
Proper orientation of the drive plates is critical for optimal clutch
performance. If you install them backwards the clutch will still
function but will lack proper modulation performance.
Oil
Face the “shark
fin” to the right.