Rekluse RadiusX Clutch Operation manual

©2018
Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[e-mail]
INSTALLATION & USER’S
GUIDE
RadiusX Clutch
for Cable Actuated Bikes and ATVs
Doc ID: 191-6300A
Revision: 040919

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TABLE OF CONTENTS
OVERVIEW ...........................................................................2
INSTALLATION TIPS ............................................................3
TOOLS NEEDED...................................................................4
INCLUDED PARTS ...............................................................4
DISASSEMBLE THE CLUTCH .............................................4
CLUTCH PACK INSTALLATION...........................................7
Notes for clutch pack installation .......................................7
Install Clutch Pack..............................................................9
SET THE INSTALLED GAP ................................................12
CHECK FREE PLAY GAin ..................................................12
Learn how to check Free Play Gain.................................13
Two Ways to Check for Free Play Gain...........................13
The Rubber Band Method................................................13
The Hand Method ............................................................15
ADJUST THE INSTALLED GAP .........................................16
BREAK-IN THE NEW CLUTCH ..........................................18
CLUTCH LEVER OPTIMIZATION.......................................20
Optimization with OE Perch Adjuster...............................20
Optimization with Rekluse Adjustable Reach Lever ........21
MAINTENANCE...................................................................21
Clutch wear ......................................................................21
Clutch parts ......................................................................22
Basket ..............................................................................22
Disk inspection examples ................................................23
NEED ADDITIONAL HELP?................................................24
OVERVIEW
This kit replaces many of the OE (Original Equipment) or
“stock” clutch parts. These parts are designed specifically for
your motorcycle to ensure optimal performance. The
following is a summary of what is replaced:

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·This kit will replace all the OE friction disks and drive
plates with a Rekluse thin friction EXP clutch pack.
·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
vehicle with the product.
·Protect 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
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.

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TOOLS NEEDED
INCLUDED PARTS
The parts included in the kit depend on the bike or ATV model. See
the Setup Sheet at the back of this manual for a list of included
parts and illustration.
You can also visit our website at www.rekluse.com/support for a full
parts fiche illustration and part numbers.
DISASSEMBLE 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.
10 mm
socket
8 mm socket
Metric
Wrench
Torque
Wrench
Pick
Fluid Catch
Container
4 mm Hex
key
4 mm

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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.
4. Remove the OE clutch access cover. Set aside. It will be
reused.
5. Remove the OE pressure plate bolts, springs, and
pressure plate.

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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.
Note: Some models have a clutch boss spring located in the
bottom of the OE friction pack. This consists of a spring, seat
and narrow friction. If your model is equipped with these
parts, remove them and set the spring aside. Only some
models will reuse the spring. Refer to the Setup Sheet at the
back of this manual to see if your model reuses these parts.

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CLUTCH PACK INSTALLATION
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 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 the following picture for
reference.
·Inspect the clutch basket for damper and/or spring play.
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.

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Failure to inspect the basket and replace if necessary
could result in death, serious injury, and/or property
damage.
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).

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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.
See following pictures for reference.
Note: When seated in the basket, the sleeve tops may sit
slightly above or below the top of the basket.
2. If the Setup Sheet at the back of this manual shows that
your bike or ATV model 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 Setup
Sheet located at the back of the manual 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
(see setup sheet at the back of this manual), install it on
top of your OEM throw-out.
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 bolts.
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. 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.
Rekluse
OE Bolts
Rekluse
springs
Rekluse
Bolts
Rekluse
Screw
Sleeves

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Note: If the clutch kit includes 2 different colors of springs,
be sure to alternate the springs. This will ensure even
pressure on the clutch.
6. Torque the pressure plate bolts in small increments in a
star pattern to OE specifications.
7. Install the clutch cover gasket based on your bike or
ATV model.
8. Reinstall the clutch cover, then reinstall the cover bolts.
9. Lightly tightening the cover bolts in a star pattern.
Torque the bolts in small increments in a star pattern
before tightening the bolts to OE specifications.
SET 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.
CHECK FREE PLAY GAIN
The proper installed gap is verified by checking Free Play
Gain.
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.
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.

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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 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.
Two Ways to Check for 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,

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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.
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 Free Play Gain will not be
correct.

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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.
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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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.
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, purchasing a new cable
should provide the necessary performance.
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.

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·
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.

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BREAK-IN THE NEW CLUTCH
Once you install your new clutch, it is important to break it in.
A series of roll-on starts are used to break in the clutch.
Follow these procedures for breaking in your clutch and any
time new friction disks, EXP bases, Teflon pads, or wedges
are installed.
Failure to follow the break-in procedure and oil screen
inspection process could cause motor oil delivery
failure, which can result in motor failure, serious injury,
or death.
Break-in Procedure
Number of times
Rev Cycles:
1.
Place the bike or ATV in
NEUTRAL.
2.
With your hand off the clutch
lever, rev the engine 10 times,
being sure to let it
return to idle
between each rev cycle.
10 rev cycles
3. With the engine still running, pull
in the clutch lever, then click the
bike/ATV into 1st
gear. Slowly
release the clutch lever. The
bike/ATV
should stay in place or
have a slight amount of forward
creep.
4.
With the bike/ATV
idling in first
gear, slowly apply throttle to
begin moving.
Continued on
next page

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5.Without using the clutch lever,
accelerate moderately to
approximately 5,000 RPM to fully
lock up the clutch and come to a
complete stop. Repeat 10 times.
Note:
If the engine wants to stall or
the creep is excessive, the idle may
be too high or the installed gap may
be too small. Make
necessary
adjustments before proceeding.
10 roll-
on starts
6.
Without using the clutch lever,
start in 2nd
gear, then accelerate
moderately to approximately
5,000 RPM and come to a
complete stop. Repeat 10 times.
10 roll-
on starts
7.
Place the bike or ATV in
NEUTRAL and recheck Free
Play Gain.
8.
Continue to step 4 to adjust the
installed gap until the Free Play
Gain of the clutch lever is 1/8” to
¼” (3 mm-6 mm).
Recheck Free Play
Gain and adjust the
installed gap
Note: Your clutch pack will expand with heat, so final
adjustment to Free Play Gain should be made when the bike
or ATV is warm. Remember not to ride without sufficient
Free Play Gain.
Do not perform 3rd gear starts with this product. Starting
in 3rd gear will burn up the clutch and decrease the
performance of this product in a short amount of time.