Rekluse RadiusX Clutch Operation manual

©2021 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[e-mail]
INSTALLATION & USER’S
GUIDE
RadiusX Clutch
for Cable Actuated Bikes and ATVs
Doc ID: 191-6300B
Revision: 101722

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TABLE OF CONTENTS
OVERVIEW .........................................................................2
INSTALLATION TIPS..........................................................3
TOOLS NEEDED.................................................................4
INCLUDED PARTS .............................................................4
DISASSEMBLING THE CLUTCH .......................................5
INSTALLING THE CLUCK PACK .......................................8
Notes for Clutch Pack Installation....................................8
Install Clutch Pack..........................................................10
SETTING THE INSTALLED GAP......................................15
CHECKING FREE PLAY GAIN.........................................15
Learning How to Check the Free Play Gain ..................15
Two Methods to Check Free Play Gain.........................16
The Rubber Band Method..............................................16
The Hand Method ..........................................................17
ADJUSTING THE INSTALLED GAP.................................19
TUNING THE EXP.............................................................21
Changing the EXP Springs ............................................21
BREAKING-IN THE NEW CLUTCH..................................23
OPTIMIZING THE CLUTCH LEVER.................................25
Optimization with OE Perch Adjuster.............................25
Optimizing the Rekluse Adjustable Reach Lever...........26
MAINTENANCE.................................................................27
Clutch Wear ...................................................................27
Clutch Parts....................................................................28
Basket ............................................................................28
Disk Inspection Examples..............................................29
NEED ADDITIONAL HELP?..............................................30
OVERVIEW

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The parts in this kit are designed specifically for your
motorcycle to optimize performance. This kit will replace
several OE (Original Equipment) components with high-
quality Rekluse components.
•The OE friction disks and drive plates will be replaced
with a Rekluse thin friction EXP clutch pack.
•The OE pressure plate springs will be replaced with
Rekluse springs.
INSTALLATION TIPS
•Read the 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
vehicle with the product.
•Protect your eyes and skin –wear
safety glasses and work gloves.
•Lay the motorcycle on its left side when replacing the
clutch. This makes working on the clutch easier and
eliminates the need to drain the oil. Catch any fuel that
may drain from the bike.
•Drain the oil from an ATV before installing the clutch.
•Use the torque specifications found in your OE service
manual.
•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

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OEM or aftermarket wet clutch. Visit www.rekluse.com to
learn more.
•This clutch pack is not legal to race with in the AMA
Limited or Stock class.
TOOLS NEEDED
INCLUDED PARTS
The parts included in the kit depend on the bike or ATV model. See
the included sheet Setup Sheet for a list of included parts and
diagram.
You can also visit our website at www.rekluse.com/support for a full
parts fiche diagram and part numbers.
10 mm
socket
8 mm socket
Metric
Wrench
Torque
Wrench
Pick
Fluid Catch
Container
4 mm Hex
key
4 mm

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DISASSEMBLING THE CLUTCH
1. Soak the Rekluse friction disks in new oil for at least 5
minutes. Make sure the friction disks are coated on both
sides.
2. If applicable, turn the fuel petcock to “OFF.”
3. For bikes, lay the bike on its left side. Catch any fluids
that might drain into a suitable container. For ATVs, drain
the oil into a suitable container before disassembly.

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4. Remove the OE clutch cover and set it aside. It will be
reused.
5. Remove the OE pressure plate bolts, springs, and
pressure plate. Set them aside; they may be reused.
Note: Throw-out washers can stick to the back of the
pressure plate. Be sure to reinstall any throw-out washers
back onto the throw-out.
6. Remove the clutch pack.

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Note: Some models have a judder spring (clutch boss
spring), a spring seat, and a narrow friction located in the
bottom of the OE friction pack. If your model is equipped with
these parts, remove them and set the spring aside. Refer
to the included Setup Sheet to determine if your model
reuses any of these parts.

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INSTALLING THE CLUCK PACK
Notes for Clutch Pack Installation
•Some OE baskets 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.
Do not use the “half slots” (see below).
•Inspect the clutch basket for damper and/or spring play.
•Inspect the clutch basket for notching. Do not install
sleeves or use this 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.

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Note: If the basket is notched or
worn, Rekluse recommends
replacing it with a Rekluse Billet
Clutch Basket (available for most
models).
•Inspect your OE center hub and pressure plate flanges for
excess wear. If wear is visible use a drop gauge to verify
that the wear across the flange does not exceed .005”
(.12mm).
•Some friction disks are marked with a small colored dot.
This mark is used for processing and can be ignored.

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Install Clutch Pack
1. Install all of the Rekluse basket sleeves into the basket
slots. Make sure the bottom of the sleeve is facing down,
and the sleeve tabs sit against the inside of the basket.
Note: When seated in the basket, the sleeve tops may sit
slightly above or below the top of the basket.
2. If the included Setup Sheet indicates your bike or ATV
reuses the judder spring, reinstall only the judder
spring, cupped side up.
3. Install the Rekluse clutch pack. The clutch pack varies
depending on the bike or ATV model. See the included
Setup Sheet for the proper clutch pack
configuration.
Sleeve tabs sit inside the
basket
Install all the
basket sleeves

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4. If your kit includes a Rekluse throw-out spacing washer,
install it on top of your OE throw-out as indicated by the
included Setup Sheet.
Suzuki RM-Z450 Models: The needle bearing only has
the bearings on one side. Make sure that the bearing
side is facing the throw-out and the flat side is facing
the pressure plate.
Flat side toward
pressure plate
Bearing side
toward throw-out

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5. Reinstall the pressure plate, then install the Rekluse
pressure plate springs and OE bolts.
Note: For Yamaha YZ250F (2019+),
YZ250FX (2020+), & WR250F
(2020+) when installing the pressure
plate align the indent in the pressure
plate with the indent in the center
hub.
Rekluse
springs
OE Bolts

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Note: DRZ 400, KLX 400, KX 500 bike models:
If your kit includes Rekluse screw sleeves or spring bolts,
install them in place of the OE components. The DRZ 400
and KLX 400 models will utilize the supplied Rekluse screw
sleeves and OE bolts, and KX 500 models will utilize
supplied Rekluse screw sleeves and Rekluse bolts.
Note: If the clutch kit includes 2 different pressure plate
spring colors, install them in an alternating pattern.This will
ensure an even force is applied to the pressure plate and
clutch.
6. Tighten the pressure plate bolts in a star-pattern to the
OE torque specifications. Tighten each bolt in small
increments, following a star-pattern.
7. Reinstall the OE clutch cover gasket.
8. Reinstall the clutch cover, then reinstall the cover bolts.
Tighten the cover bolts in a star-pattern to the OE torque
specifications. Tighten each bolt in small increments,
following a star-pattern.
Rekluse
springs
Rekluse
Bolts
Rekluse
Screw
Sleeves

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SETTING THE INSTALLED GAP
1. The clutch lever should be tight against the perch. If not,
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.
CHECKING FREE PLAY GAIN
The proper installed gap is verified by checking Free Play
Gain.
Correct Free Play Gain = Correct installed gap
Setting up, breaking-in, and rechecking the installed gap is
CRUCIAL. Failure to properly maintain the installed gap can
result in premature wear or failure of the clutch.
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.
Learning How to Check the Free Play Gain
If you are familiar with checking Free Play Gain, skip to the
“Adjusting the Installed Gap” section.
If Free Play Gain is new to you, follow the instructions below.
You can also view the video titled “How to Check Free Play
Gain” on our website at www.rekluse.com/support/videos.
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.

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Two Methods to Check Free Play Gain
There are two ways to check for 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.
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 or vehicle is in
NEUTRAL before checking Free Play Gain. Failure to do
so may result in the bike or vehicle lurching forward,
and loss of control and/or injury may result.
A Rekluse auto-clutch can make your motorcycle or
vehicle appear to be in neutral when in gear, even when
the engine is running and clutch lever released.
Motorcycles or vehicle 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 or
ATV to start it.
a) Before you begin, place the bike/ ATV in NEUTRAL, start
the engine and let it warm up for 2-3 minutes to idle down
and warm the engine oil.
b) Stretch the included rubber
band between your thumbs,
and then place the top end of
the rubber band on the outer
end of the left handlebar grip.

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c) While holding the top end of
the rubber band against the
handlebar, stretch the band
downward, and then loop it
through itself.
d) Pull the band through the loop,
and then attach it to the
outside end of the clutch lever.
e) While still in NEUTRAL, quickly rev the engine between
5,000-7,000 RPM (1/2 to ¾ 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 the Free Play Gain will not be
correct.
f) When the bike/ATV 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.
The Hand Method
a) Before you begin, place the bike/ATV 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/ATV at idle, use one finger to apply
pressure at the end of the clutch lever.

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c) While still in NEUTRAL, continue to apply light pressure
and quickly rev the engine between 5,000-7,000 RPM
(1/2 to ¾ 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/ATV 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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ADJUSTING THE INSTALLED GAP
After checking for Free Play Gain, you may need to adjust
the installed gap. If the Free Play Gain is optimal, continue to
“Breaking-In the New Clutch”. If the 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.
Notes: If you are unable to obtain the correct Free Play Gain
or you are nearly out of cable adjustment after performing
the adjustment, your cable may be worn or stretched from
wear or use. If this is the case, the cable should be replaced.

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Adjust the Installed Gap
Symptom
Reason
Solution
•Clutch lever moves
in too far (too
much Free Play
Gain)
•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:
increase the length
of the in-line cable
adjuster housing
until the correct
amount of Free Play
Gain is achieved.
Recheck Free Play
Gain.
•Clutch lever only
moves slightly or
does not move at
all (too little Free
Play Gain)
•Clutch slips
•Bike/ATV seems to
lose power
Installed gap
is too large
Loosen the cable:
Reduce the length of
the cable housing
(collapse the
adjusters) until the
correct amount of
Free Play Gain is
achieved.
Recheck Free Play
Gain.