Rekluse YXZ 1000 Operation manual

©2017 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
customer[email protected]
INSTALLATION & USER’S
GUIDE
TorqDrive Clutch
YXZ 1000
Doc ID: 191-2870A
Revision: 110617

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Table of Contents
OVERVIEW ...................................................................................3
INSTALLATION TIPS....................................................................3
TOOLS...........................................................................................4
INCLUDED PARTS.......................................................................5
DISASSEMBLE CLUTCH..............................................................6
CLUTCH INSTALLATION .............................................................8
INSTALL THE PRESSURE PLATE.............................................11
BREAK-IN....................................................................................15
SHIFTING AND OPERATION.....................................................15
MAINTENANCE...........................................................................15
DISK EXAMPLES FOR INSPECTION........................................17
NEED ADDITIONAL HELP?........................................................18

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OVERVIEW
This kit replaces many of the OE (Original Equipment) clutch
parts. The following is a summary of what is replaced:
•This kit will replace all the OE frictions and drive plates with a
Rekluse thin friction clutch pack.
•The OE pressure plate is replaced with a Rekluse pressure
plate.
•The OE pressure plate springs are replaced with high quality
Rekluse springs.
INSTALLATION TIPS
•Read the separate included Safety
Information document before
operating the vehicle with the
product installed.
•Read this entire document before
performing any steps.
•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.
•Protect eyes and skin – wear safety glasses and work gloves.
•Use the torque values listed in the instructions. Otherwise,
use the torque specifications found in your OE service
manual.
•Use clean, quality oil with the JASO-MA or JASO-MA2
certification for motorcycles for best performance.

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TOOLS
Flashlight Magnet Stick
(X2) Metric Wrench Set Torque Wrench
Pick 5 mm Hex key
Metric Socket
Set
5 mm

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INCLUDED PARTS
Item
Description
Qty.
16 Lining Plate 1
31 Spring Sleeve 6
47 Fastener 6
60.1 / 60.2 Pressure Plate Springs Blue and Red 6
68.1 Drive Plate 14
68.2 Drive Plate – Skip tooth 1
69 TorqDrive Friction Disk 16
70 Basket Sleeves 12
78 Pressure Plate Assembly 1
Not Shown Pressure Plate Springs Gold 6
Not Shown Clutch cover gasket 1
Visit www.rekluse.com/support for
a full parts fiche illustration and part numbers.

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DISASSEMBLE CLUTCH
1. Soak the included friction disks in engine oil for at least 5
minutes. Make sure the friction disks are coated on both
sides.
2. Remove the driver seat, passenger seat and center console
body panels to access to the clutch cover.
3. Remove the clutch cover bolts and clutch cover. Refer to
vehicle service manual for instructions.
•It is not necessary to drain the oil however it is
recommended to change the oil after clutch break-in.
The bolts along the bottom of the clutch cover also have copper
crush washers. Be sure to reinstall the crush washers with the
bolts in the proper locations.
4. Remove the following OE parts. See picture for reference.
•Lower clutch pack with
damper springs
•Wire circlip
•Upper clutch pack
•Pressure plate
•Spring seat
•Spring
•Spring retainer
•Bolts
To remove the lower clutch pack, you will need to remove the
wire circlip from the inner hub. To remove the wire circlip, use
needle nose pliers and/or picks. The wire circlip WILL NOT be re-
used.

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5. Ensure all parts of the lower clutch pack are removed. The
push rod, inner hub, and basket do not need to be removed.

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6. Use magnets to remove damper spring and damper spring
seat from the bottom of the lower clutch pack.
CLUTCH INSTALLATION
Clutch Pack Cutaway Overview

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1. Inspect the clutch basket for damper/cushion play or notching.
Do not install sleeves or use product with a notched basket.
Notched basket tang faces or worn dampers can cause the
sleeves to break.
Failure to inspect the basket and replace if necessary could
result in death, serious injury, and/or property damage.
2. Install all of the Rekluse basket sleeves into the basket slots.
Make sure the bottom of the sleeve is facing down, and the
long sleeve tabs sit against the inside of the basket. See
pictures for reference.
Install all the
basket sleeves

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3. Ensure damper spring, damper spring seat, and bottom narrow
friction were removed. The clutch will not install properly if
these parts are still in place.
4. Install a friction disk into the clutch basket, then install a steel
drive plate. Some friction disks are marked with a small colored
dot. This mark is used for processing and can be ignored.
Some OE basket have “half slots” at the top of the basket tangs.
Rekluse products require the entire clutch pack be installed into
the MAIN (deeper) basket slots. (These slots are lined with the
basket sleeves.) See the following picture for reference.
5. Continue to alternate 14 friction disks and 13 steel drive plates
into the clutch. You will end with a friction disk on top and have
1 friction disk left over.