Rekluse RadiusX BMW S1000 Operation manual

Doc ID:191-6309001A
Revision:
101619 ©2019
Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[email protected]
INSTALLATION & USER’S
GUIDE
RadiusX
BMW S1000/S1000RR/S1000XR/HP4

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TABLE OF CONTENTS
OVERVIEW ..........................................................................3
INSTALLATION TIPS ...........................................................3
TOOLS NEEDED .................................................................4
INCLUDED PARTS ..............................................................5
DISASSEMBLE THE CLUTCH.............................................7
CLUTCH PACK INSTALLATION ..........................................9
Notes for installation.........................................................9
Clutch pack ......................................................................9
PRESSURE PLATE INSTALLATION .................................13
SET THE INSTALLED GAP ...............................................15
CHECK FREE PLAY GAIN.................................................17
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
ADJUST THE INSTALLED GAP ........................................24
BREAK IN THE NEW CLUTCH..........................................26
EXP TUNING OPTIONS.....................................................28
Changing the EXP springs..................................................28
SHIFTING AND OPERATION ............................................31
MAINTENANCE .................................................................31
Disk inspection examples ...............................................32
TROUBLESHOOTING .......................................................33
BUMP-STARTING INSTRUCTIONS ..................................33
NEED ADDITIONAL HELP? ...............................................34

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This kit replaces the OE (Original Equipment) or “stock”
clutch pack with a Rekluse-designed high quality clutch pack
designed specifically for your bike model. The following is a
summary of what is replaced:
·All OE steel drive plates will be replaced with Rekluse
drive plates
·All OE friction disks will be replaced with Rekluse
TorqDrive®disks
·The OE pressure plate springs will be replaced.
·Read this entire document before performing any steps.
·Read the safety information sheet included with your kit.
·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 thin disposable
work gloves. Work in a well
ventilated area.
·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.
·Use the torque values listed in the instructions.
Otherwise, use the torque specifications found in your
OE service manual.
OVERVIEW
INSTALLATION TIPS

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·Torx 30
·Torx 25
·5mm Allen
·Torque wrench
·Pick set
·10mm Wrench
·Standard Screw Driver
TOOLS NEEDED

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INCLUDED PARTS
Item
Description
Qty.
70
Basket sleeves
12
68
Steel drive plates - .060” (1.5 mm)
5
65.1
Steel drive plates - .048” (1.2 mm)
1
63
Steel drive plates - .040” (1.0 mm)
2
65
Steel drive plates - .048” (1.2 mm)
2
69.1
TorqDrive® friction disks
7
69
TorqDrive® friction disks - .110” (2.8mm)
2
60.1
Pressure plate springs
3
60
EXP adjustment spring –silver
6
51
Fastener - 1/4-Turn Pin (includes 2 extra)
8
13
EXP bases
2
85
Wedge assembly
6

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Visit www.rekluse.com/support for a full parts fiche
illustration and part numbers.
Not Shown
EXP adjustment spring –red
3
Not Shown
EXP adjustment spring –steel
3
Not Shown
Velcro straps
2
Not Shown
Orange Free Play Gain rubber band
1
Not Shown
Clutch lever warning label
1

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1. Remove the 3 bolts securing the right side cowling to the
frame using a T25 torx.
2. With the bike on its side stand, use a T30 Torx to remove
the clutch cover bolts. There are 2 bolts behind the right-
side cowling.
3. With all the clutch cover bolts removed gently remove the
clutch cover. Set the OEM clutch cover bolts to the side
they will not be reused.
DISASSEMBLE THE CLUTCH
Remove cowling bolts

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4. Use a 5 mm Allen to remove the following OE parts:
NOTE: Items 2, 3, & 5 are not reused with the Rekluse clutch
pack and can be set aside.
1
Pressure plate bolts
2
Pressure plate spring retainer
3
Pressure plate springs
4
Pressure plate
& throwout rod
5
Clutch pack
6
Judder seat and spring
5
3
2
1
6
4

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Notes for 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
clutch pack into the “half slots” will cause performance
issues. See the following picture for reference.
Clutch pack
1.Soak the EXP disk and all friction disks
in engine oil for 5 minutes. Make sure
the EXP and friction disks are coated on
both sides.
2.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.
CLUTCH PACK INSTALLATION
Use main (deeper)
basket slots
Representative image. Basket may appear different than the stock basket.

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Failure to inspect the basket and replace if necessary
could result in death, serious injury, and/or property
damage.
3.Install ALL the Rekluse basket sleeves into the basket
slots. Make sure the sleeve tabs sit against the inside of
the basket, then push the sleeves down until they contact
the bottom of the tang slot. See pictures for reference.
NOTE: When seated in the basket slots, the sleeves will sit
flush or slightly above the top of the basket tangs. This is
normal.
OE basket
Basket sleeve
Representative image. Basket may appear different than the stock basket.
Representative image. Basket may appear different than the stock basket.

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4.Install the EXP as the first friction into the basket.
5.Install a .048” (1.2 mm) steel drive plate followed by a
thin friction.
6.Continue to alternate four .048” (1.2 mm) steel drive
plates with four thin friction disks
EXP disk
EXP disk
Section total:
5 steel drive plates - .048” (1.2 mm) and
5 thin friction disks
Commented [BB1]: .048 or .060?

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7.Install a .060” (1.5 mm) steel drive plate followed by a
thin friction.
8.Continue to alternate three .060” (1.5 mm) steel drive
plates with three thin friction disks
9.Install a .060” (1.5 mm) steel drive plate followed by the
judder friction disk.
10. Install the judder spring Cupped side in followed by the
judder seat.
11. Install a .060” (1.5 mm) steel drive plate followed by
a thick friction disk.
Section total:
6 steel drive plates - .060” (1.5 mm)
4 thin friction disk, 1Judder friction disk, & 1 Thick
Fiction
Judder Friction
Thick Friction
Judder Spring & Seat
Commented [BB2]: Moved this section to match page
with diagram

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1. . Reinstall the OE throw-out rod into the main shaft.
2. Install the pressure plate making sure the alignment teeth
index into the hub.
3. Install the Rekluse pressure plate springs.
Note: Be sure to alternate springs if you are using two
different color springs to keep even pressure on the clutch.
4. Reinstall the OE pressure plate bolts using Rekluse
provided screw sleeves.
PRESSURE PLATE INSTALLATION
Rekluse springs –
alternate colors
OE bolts
OE pressure plate
Rekluse screw
sleeves
Commented [BB3]: No step removing the oe throwout

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5.Lightly tighten the bolts until the bolt is tight against the
standoff. You will torque the bolts and install the cover
after setting the install gap in the next section.

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The “installed gap” is the separation in the clutch pack
created by tension adjusted into the clutch cable. This gap
is what allows the clutch to spin freely until the desired RPM
is reached for engagement. The installed gap must be set
correctly for optimal performance.
1.Adjust the inline perch adjuster to the midway or center
position.
2.Using a 10mm wrench and a standard screwdriver loosen
the lock nut on the thrust adapter.
3. Tighten the throw-out until there is no free play between
the pressure plate. Once there is no free play loosen the
pressure plate bolts.
4.With the pressure plate bolts loose turn the center screw of
the throw-out 3 turns then lock the nut against the adapter.
5.Torque the Pressure plate bolts in a pattern, working
clockwise to apply final torque of 89 in-lb (10 N-m).
SET THE INSTALLED GAP
Perch Adjuster
Commented [BB4]: Thrust adapter or throwout?

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6. Reinstall the clutch cover, then lightly tightening the
cover bolts in the following pattern. Tighten bolts in small
increments before torqueing the cover bolts. DO NOT
REUSE ORIGINAL BOLTS. Use rekluse provided bolts or
order new bmw bolts part # 1114724485 Qty: 9
·Rekluse provided bolts 80 in-lb (9 nm)
·New OEM bolts 26 in-lb (3nm) + 90°.
7. Reinstall the 3 side cowling bolts.
8.Install the provided warning sticker on the backside of the
clutch lever, such that it is visible to the rider.
9.To set the final installed gap, check Free Play Gain. The
directions are in the next section.
NOTE: Final free play gain should be achievable through
the inline perch adjuster on the handlebar. If proper free
play gain is not achieved through the perch adjuster, you
will need to remove the clutch cover and adjust the throw-
out.

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FNOTE: When adjusted properly you will no longer have
lever free play. The lever will be tight against the perch,
this is normal.
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, Verify Free
Play Gain then skip to the “Break in the New Clutch” 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.
CHECK FREE PLAY GAIN

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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.”
·If there is too much Free Play Gain, the installed gap
is too small.
oThe vehicle may drag and stall because it has
difficulty disengaging the clutch. It may also be
difficult to shift.
oToo much Free Play Gain will not hurt the clutch, but
it will negatively affect clutch performance.
Lever position at
idle
Lever position
around 4,000 RPM
Free Play Gain
1/8”-1/4” (3 mm-
6 mm) lever movement
Le
Le
Le
arou
Free Play
Gain

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·With too little or no Free Play Gain, the installed gap is
too large.
oThis means when the EXP is fully expanded it does
not lift the pressure plate. The clutch may slip and
make the vehicle seem like it is losing power.
oThe vehicle may not move forward even though the
engine RPM increases as if the clutch lever is
slightly pulled.
oToo little Free Play Gain will cause the clutch system
to burn up and fail.
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 Free Play Gain.
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.
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.
The Rubber Band Method

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BEFORE YOU BEGIN, verify that the vehicle is in
NEUTRAL before checking Free Play Gain. Failure to do
so may result in the vehicle 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 warm up the
engine oil. The bike will idle down after the cold start
procedure.
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.