Rekluse RadiusCX Operation manual

©2017 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[e-mail]
INSTALLATION & USER’S
GUIDE
RadiusCX Clutch
For KTM/Husqvarna DS Clutches
Doc ID: 191-7913A
Revision: 082018

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Doc Rev: 082018
TABLE OF CONTENTS
OVERVIEW ................................................................................3
INSTALLATION TIPS.................................................................3
Tuning Note ............................................................................4
TOOLS NEEDED .......................................................................4
INCLUDED PARTS ....................................................................5
DISASSEMBLE THE CLUTCH ..................................................7
CLUTCH PACK INSTALLATION..............................................10
Notes for Clutch Pack Installation:........................................10
Clutch pack overview............................................................14
PRESSURE PLATE INSTALLATION.......................................15
SLAVE CYLINDER INSTALLATION ........................................19
Step 1: Bleed the new slave cylinder....................................19
Step 2: Replace OE slave cylinder .......................................22
BLEED THE CLUTCH LINE.....................................................26
SET THE INSTALLED GAP .....................................................29
Step 1: Find the starting point...............................................30
Step 2: Learn how to check Free Play Gain .........................31
Two Ways to Check for Free Play Gain................................32
The Rubber Band Method ....................................................32
The Hand Method.................................................................34
Step 3: Break-in the new clutch............................................35
Step 4: Adjust the installed gap and Recheck Free Play Gain
..............................................................................................37
FREE PLAY GAIN ADJUSTMENTS.........................................39
MAINTENANCE .......................................................................40
Disk inspection examples .....................................................41
TROUBLESHOOTING .............................................................42
Performance issues..............................................................42
Clutch noise..........................................................................43
EXP TUNING OPTIONS ..........................................................43
Configuration chart ...............................................................44
Changing the springs............................................................44
BUMP-STARTING....................................................................46
NEED ADDITIONAL HELP?.....................................................47

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OVERVIEW
This kit replaces many of the OE (Original Equipment) clutch
parts while reusing some of the OE clutch parts. These parts
are designed specifically for your motorcycle to ensure
optimal performance. The following is a summary of what is
replaced.
•The OE center clutch hub, pressure plate, clutch cover,
and clutch pack are replaced with high-quality billet
components.
•All OE steel drive plates will be replaced with Rekluse
TEC drive plates.
•All OE friction disks will be replaced with Rekluse
TorqDrive®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 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.
•Use clean, quality JASO-MA or JASO-MA2 certified
transmission oil for best performance.

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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 part number is KTM Part #: 78932005000
TOOLS NEEDED
•4 mm hex key •Torque wrench
•5 mm hex key •Fluid catch container
•8 mm socket •Channel-lock pliers
•27 mm socket •T-25 Torx bit (provided)

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INCLUDED PARTS
Item
Description
Qty.
27
Center hub
1
69
Steel drive plates
8
63
TorqDrive®friction disks
7
16
Lining plate
1
13
EXP base
2
85
EXP wedge assembly
6
60 / 60.1
EXP adjustment springs (colors vary)
15
51
Quarter turn pins (includes 2 extra)
8

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5
Pressure plate
1
23
Clutch cover
1
30
Tab lock washer
1
86
Adjustable slave cylinder assembly
1
Not shown
Torx head screws (T-25 Torx bit
included)
6
Not shown
Orange Free Play Gain rubber band
1
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. Remove the following OE parts. When removing the
Bellville spring, make sure to note the orientation of the
spring. See following picture for reference.

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1 6 pressure plate screws
2
Spring ring
3 Belleville spring
4
Slider ring
5 Pressure plate
6
Throw-out bearing and washer
7 Clutch pack
8
6 Drive pins
Be careful that the drive pins
do not fall into the engine
while disassembling.
5
8
7
6
4
3
2
1

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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 OE tab washer.
7.Remove the OE center hub from the clutch basket while
leaving the thrust washer on the main shaft.
NOTE: 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.
Thrust washer
OE Inner hub

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CLUTCH PACK INSTALLATION
The clutch pull effort has different settings and depends on
the thickness of the clutch pack. You will need to measure
the clutch pack before you begin if you wish to optimize the
clutch pull effort vs. clutch performance. Please refer to the
Setup Sheet located at the back of the manual for clutch
pack specifications and information.
Notes for Clutch Pack Installation:
•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. Installing the pack in the “half slots” will cause
performance issues. See the following picture for
reference.
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.
Use main (deeper) basket slots

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2. Install the new Rekluse center hub into the clutch
basket. Make sure the thrush washer is still in place.
3. Reinstall the new Rekluse tab washer and center clutch
nut.
4. Using the 27 mm socket and
torque wrench, torque the center
clutch nut to 50 ft-lb (68 N-m).
5. Using the channel-lock pliers,
bend up both tabs of the tab
washer around the nut.
6. Seat the 6 OE drive pins into
the Rekluse inner hub.
Thrust
washer
Rekluse
inner hub

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7. Hold a TEC drive plate so thatthe “shark fin” notches face
toward the right. All the drive plates will follow this
orientation.
Note: 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.
8. Align the drive pin notches in the steel drive plate with
the drive pins on the hub, then install the drive plate into
the basket. Be sure that the drive pins are seated in the
notches and not in the bigger sections.
Drive pin notches
Drive pins
Install steel drive
plate first
Face the “shark fin”
to the right.

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Note: ALL the steel drive plates must be aligned in the
drive pins notches or damage may occur. The plates will
not move when installed correctly.
9. On top of the steel drive plate, install a Rekluse fiction
disk.
10. Continue alternating the steel drive plates with the
friction disks for the entire Rekluse clutch pack. There
will be a total of 8 steel drive plates and 7 frictions
disks. See the following picture for reference.
11. Install the EXP disk on top of the last steel drive plate.
Make sure the EXP disk is seated in the main basket
slots along with the clutch pack.

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Clutch pack overview
1 Steel drive plate
2 TorqDrive friction disk
3 Alternate steel drive plates with friction disks
4 EXP disk
5 Total clutch pack:
8 steel drive plates and 7 friction disks
4
2
1
3
5

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12. Reinstall the OE throw-out.
PRESSURE PLATE INSTALLATION
1. Add a light film of oil between the lining plate and
pressure plate. This will help the plates stick together for
ease of installation.
2. Install the supplied lining plate onto the new Rekluse
pressure plate by lining up the index tabs into the slots.

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3. Install the pressure plate subassembly by lining up the
index tabs on the pressure plate with the slots in the hub.
NOTE: When the pressure plate is seated correctly, the
threaded standoffs will come through the openings of the
pressure plate.
4. Place the OE slider ring on the pressure plate with the
“top” marking facing up. (The top side is rounded and the
bottom edge is sharp.)
Pressure
plate with
lining plate
Index to
hub slots

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5. Place the OE Belleville spring onto the slider ring, with the
rounded dome side facing up.
NOTE: The outer edge of the Bellville spring will make
contact with the slider ring. If it does not, the Bellville spring
is upside down.
6. Install the OE pressure ring, flat side up.
NOTE: There are 3 possible settings on the OE pressure
ring. Please refer to the Setup Sheet at the back of the
manual for optimized pressure ring setting. For a simple
setting, set it to setting II (4-strokes and 2017 + 2-
strokes) or X (pre 2017 2-strokes). In most cases, this is
the best starting point for the clutch.
7. Install the Rekluse pressure plate screws.
Do not reuse the OE screws, or clutch cover
interference will occur!
Incorrect – The
Belleville spring is upside
down.
Correct – The Belleville
spring sits flat against the
slider ring.

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8. Loosely tighten the screws, then use the T-25 Torx bit
and torque wrench to tighten the screws in a star pattern
to 55 in-lb (6 N-m).
9. Remove the OE cover gasket from the OE clutch cover
and install it onto the new Rekluse clutch cover.
10.Install the Rekluse clutch cover, then lightly tightening
the cover bolts in a star pattern. Tighten bolts in small
increments before torqueing the cover bolts to OE
specifications.
NOTE: If your bike has an oil plug, transfer the OE oil
plug to the new Rekluse clutch cover.
Rekluse
pressure plate
screws
OE spring ring-
flat side up

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SLAVE CYLINDER INSTALLATION
Installing the new Rekluse slave cylinder takes several
steps. Please read the entire section before beginning the
process to ensure you have the right equipment and clutch
fluid needed for the replacement. Rekluse recommends
wearing gloves and safety glasses for the install.
During the bleed and assembly,
note that there is a small ball
bearing installed in the slave piston
with a small amount of grease.
When installing the Rekluse slave
cylinder, make sure the ball is in
place and has not come loose.
Step 1: Bleed the new slave cylinder
This step prepares the new slave cylinder for installation.
Bleed the cylinder on a workbench or an area away from the
bike.
1. Using a 4 mm hex key, turn the adjuster screw
counterclockwise so that the top O-ring is visible under
the adjuster screw.

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2. Use your thumbs to compress the
piston until it bottoms out, then release
it.
3. Pour the recommended clutch fluid into
the slave cylinder port.
Be sure to use the correct clutch fluid. Check the cap of
the clutch master cylinder to determine which clutch
fluid to use. Failure to use the correct fluid will result in
seal damage and/or failure.
4. Use a 4 mm hex key to turn the
adjuster screw clockwise until it
bottoms out and the O-ring in no
longer visible. Keep the fluid
topped off as you go.