Rekluse RadiusCX Clutch Upgrade Kit Operation manual

©2017 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[e-mail]
INSTALLATION & USER’S GUIDE
RadiusCX Clutch Upgrade Kit
For KTM/Husqvarna DDS clutches
Doc ID: 191-7911A
Revision: 080420

Pg.
2 Doc ID: 191-7911A
Doc Rev: 080420
TABLE OF CONTENTS
OVERVIEW..................................................................................... 3
INSTALLATION TIPS...................................................................... 3
Tuning Note.................................................................................. 4
TOOLS ............................................................................................ 4
INCLUDED PARTS ......................................................................... 5
DISASSEMBLE THE CLUTCH ....................................................... 6
INSPECT THE DAMPERS.............................................................. 8
CLUTCH PACK INSTALLATION..................................................... 8
PRESSURE PLATE INSTALLATION............................................ 11
SET THE INSTALLED GAP AND VERIFY BY CHECKING FREE
PLAY GAIN ................................................................................... 15
Step 1: Find the starting point..................................................... 16
Step 2: Learn how to check Free Play Gain ............................... 17
Two Ways to Check for Free Play Gain ..................................... 19
The Rubber Band Method .......................................................... 19
The Hand Method....................................................................... 22
Step 3: Break-in the new clutch.................................................. 24
Step 4: Adjust the installed gap and Recheck Free Play Gain ... 26
FREE PLAY GAIN ADJUSTMENTS ............................................. 28
MAINTENANCE ............................................................................ 29
Disk inspection examples........................................................... 31
TROUBLESHOOTING .................................................................. 32
Performance issues.................................................................... 32
Clutch noise................................................................................ 32
EXP TUNING OPTIONS ............................................................... 32
Changing the springs ................................................................. 33
Configuration chart ..................................................................... 35
BUMP-STARTING THE BIKE ....................................................... 35
NEED ADDITIONAL HELP? ......................................................... 36

Doc ID: 191-7911A
Doc Rev: 080420
Pg. 3
OVERVIEW
This guide shows you how to replace your OE (Original Equipment)
core clutch parts with your new Rekluse upgraded clutch parts. The
following parts are replaced:
·Core EXP 3.0 Drive Plates
·OE Friction Disks
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 any steps.
·Lay the bike on its left side when replacing the clutch. This
makes the clutch work easier and eliminates the need to drain
the oil.
·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.
·Bikes with taller gearing or modified engines with increased
horsepower may require heavier wedges. These can be
purchased separately from Rekluse.

Pg.
4 Doc ID: 191-7911A
Doc Rev: 080420
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
TOOLS
4 mm
Allen Wrench
8
mm Socket
Torque Wrench
T-25 Torx
Bit
Oil
Calipers
Fluid Catch
Container
8 mm
4 mm
Oil

Doc ID: 191-7911A
Doc Rev: 080420
Pg. 5
INCLUDED PARTS
Visit www.rekluse.com/support for
a full parts fiche illustration and part numbers.
Item
Description
Qty.
63
TEC Steel Drive Plate
9
69
TorqDrive
®
Friction
8