Rekluse RADIUSX BMW F650 User manual

©2015 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
customer[email protected]om
INSTALLATION GUIDE
For BMW F650, F700, F800 Parallel Twins
Doc ID: 191-6305A
Revision: 101818

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Table of Contents
OVERVIEW ...................................................................................2
INSTALLATION TIPS ....................................................................3
TOOLS...........................................................................................3
INCLUDED PARTS .......................................................................4
USE OF OTHER AFTERMARKET PRODUCTS ..........................5
DISASSEMBLE CLUTCH..............................................................6
INSTALL THE CLUTCH PACK .....................................................9
Notes for installation..................................................................9
Clutch pack..............................................................................10
SET THE INSTALLED GAP ........................................................14
CHECK FREE PLAY GAIN .........................................................15
Learn how to check Free Play Gain........................................15
Two Ways to Check for Free Play Gain..................................16
The Rubber Band Method.......................................................17
The Hand Method....................................................................19
ADJUST THE INSTALLED GAP .................................................20
CLUTCH PACK ADJUSTMENT ..................................................21
BREAK IN THE NEW CLUTCH...................................................23
EXP TUNING OPTIONS .............................................................24
Changing the springs ..............................................................25
MAINTENANCE...........................................................................27
Clutch wear .............................................................................27
Clutch parts .............................................................................27
Basket .....................................................................................28
Disk inspection examples........................................................28
LEVER SAFETY STRAPS ..........................................................29
NEED ADDITIONAL HELP?........................................................30
OVERVIEW
This kit replaces the OE (Original Equipment) or “stock” clutch
pack with Rekluse high quality billet components designed
specifically for your bike model.
•This kit will replace all the OE frictions and drive plates with a
Rekluse TorqDrive®clutch pack and EXP disk.

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•This kit includes extra EXP springs, which can be used to
tune for your desired engagement. See the EXP tuning
options section in this document for specific tuning
information.
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
Installation Guide before operating the bike with the product.
•Lay the bike on its left side when replacing the clutch. This
makes working on the clutch easier and eliminates the need to
drain the oil.
•Protect eyes and skin – wear safety glasses and work gloves.
Work in a well ventilated area.
•Use the torque values listed in the instructions. Otherwise, use
the torque specifications found in your OE service manual.
•Use clean, quality JASO-MA or JASO-MA2 certified
transmission oil for best performance.
•Inspect your OE cable for fraying and replace if needed.
TOOLS
•6, 8, & 24 mm sockets
•2x 13 mm end wrenches
•Channel-lock style pliers
•2x dental pick tools
•5 mm hex key
•Torque wrench
(in-lb, or N-m)
•T45 Torx bit

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INCLUDED PARTS
Item
Description
Qty.
13 EXP bases 2
85 Wedge assembly 6
51 Quarter-turn pins (extra included) 8
60.1, 60.2 EXP adjustment springs – colors vary 12
63 Steel drive plate - .040” (1 mm) thick 9
68 Steel drive plate - .060” (1.5 mm) thick 3
69.1
Thick TorqDrive®friction disk - .124” (3.15
mm)
1
69.2 TorqDrive®friction disks 9
70 Basket sleeves 12
Not shown Velcro straps 2
Not shown Orange Free Play Gain rubber band 1
Not shown Clutch lever warning label 1
Visit rekluse.com/support for a full parts fiche illustration and part numbers.

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USE OF OTHER AFTERMARKET
PRODUCTS
•Bikes with heavily modified engines for increased horsepower
may require stiffer pressure plate springs which can be
purchased separately from Rekluse.
•If your bike is equipped with an aftermarket clutch cable, you
may find that the adjustment range in your cable is different
from described in this manual.
•Bar risers may limit the travel necessary for your cable
adjustment to achieve the necessary installed gap.
•If you prefer the use of an aftermarket clutch lever and/or
perch, especially the adjustable variety, note that:
oSome aftermarket lever/perch combos claim “Lighter
Lever Pull” which correlates to less lift of the pressure
plate (the mechanical advantage is increased, so the
distance the pressure plate lifts must decrease).
oThis may have an adverse effect by producing more
clutch drag or harder shifts. The lever may be lighter, but
you will have to pull the lever in farther to disengage the
clutch.
•Some aftermarket lever/perch combos may provide lever
“free play” if desirable.
•This product has not been proven to be compatible with
hydraulic conversion kits, as it is difficult to achieve the
necessary adjustment for installed gap.

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DISASSEMBLE CLUTCH
1.Soak the EXP disk and TorqDrive®friction disks in
primary/transmission oil for 5 minutes. Make sure the EXP and
friction disks are coated on both sides.
2.Lay the bike on its right side. Catch any fuel that might drain in
a suitable container. Or you can stand the bike vertically on its
center and drain the oil.
3.Remove the left side kickstand bracket using a T45 Torx, then
remove the shift lever using a 6 mm socket. Take care not to
damage the electronics or wires that protrude from the
kickstand bracket.
4.Loosen the jam nut and unthread it
from the cable adjuster.
5.Use channel-lock style pliers to turn
the actuator arm, then detach the
clutch cable from the actuator arm
and the clutch cover.

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6.Remove the clutch cable from
the clutch cover.
7.Remove the oil fill cap.
8.Remove the
clutch cover bolts
and clutch cover,
taking care not to
damage the cover
gasket. Replace
this gasket if it is
torn or damaged.
Note: The washer
on the shifter shaft
may stick to the
back of the clutch
cover when
removing it. Ensure
that the washer is
placed on the
shifter shaft.

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9.Remove the OE pressure plate bolts and springs, throw-out,
and pressure plate.
10. Remove the entire OE clutch pack.

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INSTALL THE CLUTCH PACK
Notes for installation
•Some friction disks are marked with a small colored dot. This
mark is used for processing and can be ignored.
•Inspect the clutch basket for notching. Do not install sleeves
or use product with a notched basket. Notched basket tang
faces can cause the sleeves to break. Do not use baskets that
have been filed, machined, or modified on the tangs. Replace
basket if necessary.
Failure to inspect the basket and replace if necessary could
result in death, serious injury, and/or property damage.
•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.
Do not use
the “half-
slots”
Use only
the deeper
basket
slots for
installation

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Clutch pack
NOTE: The OE top and bottom friction disks have slightly
narrower tabs than the other 7 friction disks. The Rekluse
supplied thick friction disk also has this same narrow-tab feature
so that it fits properly into the slots of the OE basket.
1.Install a .060” (1.5 mm) thick steel drive plate into the clutch
basket first.
2.Install a .124” (3.15 mm) thick friction disk, then install another
.060” (1.5 mm) thick steel drive plate.
3.Install ALL the Rekluse basket sleeves into the OE basket
slots with the tabbed side facing toward the inside of the clutch
basket. Push the down until they contact the tabs of the first
thick friction disk.
BASKET
TANG
BASKET
SLEEVE
3rd-Thick
steel drive
1st-Thick steel
drive plate
2nd-Thick friction disk

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4.Install a thin friction disk, then install a .040” (1 mm) thin steel
drive plate. Continue to alternate thin friction disks with thin
steel drive plates for the entire clutch pack. There will be 1
thick steel drive plate left that will be installed in a later step.
Note: Use dental picks can help control the basket sleeves when
installing the clutch pack.
5.Install the Rekluse EXP disk, then install the last thick drive
plate. Remember to install the EXP and drive plate into the
main basket slots with the clutch pack.
Thin friction disks
Thin steel drive plates
Total of 9 friction disks and 9 steel drive plates
Thick steel
drive plate
EXP disk

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6.Reinstall the OE throw-out and pressure plate, followed by the
pressure plate springs and bolts.
7.Torque the pressure plate bolts in a star pattern to OE
specifications.
8.Install a new clutch cover gasket followed by the clutch cover.
Make sure that the throw-out is aligned correctly with the
actuator mechanism in the cover.
9.Tighten the cover bolts in small increments in a star pattern,
then torque the cover bolts to OE specifications.
Throw-out
Pressure plate
Springs and
bolts

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10. Reinstall the left side kickstand bracket and the shift lever.
Use Loctite 243 or equivalent thread-locking compound, then
torque to OE specifications.
11. Reinstall the clutch cable to the clutch cover. Thread the jam
nut onto the adjuster, but do not tighten it. It will be tightened
after you set the Free Play Gain.
12. Use the channel-lock pliers to reattach the clutch cable to the
clutch cover and the actuator arm.
13. Stand the bike up, supporting it on its kickstand or center
stand.
14. Install the provided warning sticker on the backside of the
clutch lever, such that it is visible to the rider.

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SET THE INSTALLED GAP
The installed gap is the separation in the clutch pack created by
adjusting the tension in the clutch cable. This gap is what allows
the clutch to spin freely until the desired RPM is reached for
engagement. The gap must be set correctly for optimal
performance.
1. The clutch lever should be tight against the perch. If not, use
the adjustment nut to adjust the cable so that the lever is tight
against the perch.
2. Turn the cable and/or perch adjuster 3-5 turns tighter.
Tightening beyond the initial perch adjustment creates the
installed gap.
3. Continue the installation by checking for Free Play Gain.
Do not ride your bike without adjusting the installed gap.
You will not be able to disengage the clutch until you set the
installed gap.

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CHECK FREE PLAY GAIN
It is very important that you understand how to verify the correct
installed gap by checking Free Play Gain. The installed gap is
what allows the auto function of the product to perform properly.
Correct Free Play Gain = Correct installed gap
Setup, break-in, and rechecking the installed gap is CRUCIAL.
Failure to properly maintain your installed gap can result in
premature wear or failure of your clutch. Use the following steps
to verify the installed gap by checking Free Play Gain.
Failure to check and verify Free Play Gain can cause failure
or damage to this product.Setting the correct installed gap
is critical for clutch performance.
Learn how to check Free Play Gain
If you are familiar with checking Free Play Gain, check for Free
Play Gain then skip to the “Adjust the Installed Gap” section.
If Free Play Gain is new to you, follow the instructions below to
help you learn this important step. You can also view the video
entitled “How to Check Free Play Gain” on our website at
https://rekluse.com/support/videos.
Checking Free Play Gain allows you to externally monitor the
installed gap so you can know when to make an adjustment if the
installed gap is too large or too small.
The correct installed gap is verified by observing and feeling the
increased free play movement in the clutch lever. This extra
movement is called “Free Play Gain.”

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Optimal Free Play Gain yields 1/8”-1/4” (3 mm-6 mm) of
clutch lever movement, measured at the ball end of the lever.
This measurement at the lever correlates to achieving the ideal
installed gap.
Two Ways to Check for Free Play Gain
The following steps explain 2 ways to check Free Play Gain. One
way uses the rubber band Rekluse includes in the clutch kit, and
one uses your hand. You can use either method to check for Free
Play Gain.
Lever with “slack”
removed
Lever position around
5,000 RPM
Free Play Gain
1/8”-1/4” (3 mm-6 mm)
lever movement

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Rekluse recommends that you begin with the rubber band
method first to check for Free Play Gain and then learn the hand
method. The rubber band will help you learn how to recognize
Free Play Gain until you are comfortable with the hand method.
Learning to check Free Play Gain by hand effectively and
comfortably can make it easy to check Free Play Gain every time
you ride.
The Rubber Band Method
Use the rubber band method for the initial set up. It can also be
used before each ride until you feel comfortable checking the
Free Play Gain using the hand method.
BEFORE YOU BEGIN, verify that the bike is in NEUTRAL
before checking Free Play Gain. Failure to do so may result
in the bike lurching forward, and loss of control and/or injury
may result.
A Rekluse auto-clutch can make your motorcycle appear to
be in neutral when in gear, even when the engine is running
and clutch lever released.
Motorcycles equipped with a Rekluse auto-clutch can move
suddenly and unexpectedly and cause riders to lose control.
To avoid death, serious injury, and/or property damage,
always sit on the motorcycle to start it.
a) Before you begin, place the bike in NEUTRAL, start the
engine and let it warm up for 2-3 minutes to idle down and
warm the engine oil.

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b) Stretch the included
rubber band between
your thumbs, then place
the top end of the
rubber band on the
outer end of the left
handlebar grip.
c) While holding the top end
of the rubber band
against the handlebar,
stretch the band
downward, then loop it
through itself.
d) Pull the band through the
loop, then attach it to the
outside end of the clutch
lever. This will take up
the initial free play (slack)
and put the lever in a
position to detect the
Free Play Gain.
e) While still in NEUTRAL, quickly rev the engine between
5,000-7,000 RPM (1/4 to 1/2 throttle), then let it return to
idle. Notice the movement in the clutch lever when the
engine is revved. This is your Free Play Gain.
Note: It is very important the motor returns to idle before revving
the engine again or Free Play Gain will not be correct.
f) When the bike returns to idle, rest your hand across the
clutch lever. Rev the engine again to 5,000-7,000 RPM so
you can observe the movement while feeling for Free Play
Gain with your hand.

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The Hand Method
Use the hand method to check Free Play Gain before the start of
every ride for optimum performance and longevity of your new
clutch.
a) Before you begin, place the bike in NEUTRAL, start the
engine and let it warm up for 2-3 minutes to idle down and
warm up the engine oil.
b) With the bike at idle, apply enough pressure to the clutch
lever to take up the initial free play (slack) in the clutch lever.
c) While still in NEUTRAL, continue to apply light pressure and
quickly rev the engine between 5,000-7,000 RPM (1/4 to 1/2
throttle), then let it return to idle. Notice the movement in the
clutch lever when the engine is revved. This is your Free
Play Gain.
d) When the bike returns to idle, rev the engine between 5,000-
7,000 RPM a second time to verify the Free Play Gain again.

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ADJUST THE INSTALLED GAP
After checking for Free Play Gain, you may need to adjust the
installed gap. If Free Play Gain is optimal, continue to “BREAK IN
THE NEW CLUTCH.” If Free Play Gain is not optimal, the
installed gap needs to be adjusted.
The installed gap should be fine-tuned in small increments and
then recheck Free Play Gain. Refer to the table below to set the
proper installed gap based on your Free Play Gain.
Symptom Reason Solution
•Too much Free Play
Gain: Clutch lever
moves in too far
•Clutch has
excessive drag or
stalls
•It is difficult to fully
override the clutch
with the lever
Installed gap is
too small
Tighten the cable by
turning the adjuster
nut to increase the
Installed Gap.
Recheck Free Play
Gain.
•Too little Free Play
Gain: Clutch lever
only moves slightly
or does not move at
all
•Clutch slips
•Bike seems to lose
power
Installed gap is
too large
Loosen the cable by
tuning the adjuster nut
to reduce the Installed
Gap.
Recheck Free Play
Gain.