Rekluse RadiusX Clutch Operation manual

©2019 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[e-mail]
INSTALLATION & USER’S
GUIDE
RadiusX Clutch
for Pull-Style, Cable Actuated Street Bikes
Doc ID: 191-6313A
Revision: 041819

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TABLE OF CONTENTS
OVERVIEW ...........................................................................3
INSTALLATION TIPS............................................................3
TOOLS NEEDED...................................................................5
INCLUDED PARTS ...............................................................5
DISASSEMBLE THE CLUTCH .............................................5
CLUTCH PACK INSTALLATION...........................................8
Notes for clutch pack installation .......................................8
Install Clutch Pack............................................................11
CLUTCH COVER INSTALLATION......................................13
SET THE INSTALLED GAP ................................................16
CHECK FREE PLAY GAIN..................................................16
Learn how to check Free Play Gain.................................16
Two Ways to Check for Free Play Gain...........................17
The Rubber Band Method................................................17
The Hand Method ............................................................19
ADJUST THE INSTALLED GAP.........................................19
BREAK-IN THE NEW CLUTCH ..........................................21
CLUTCH LEVER OPTIMIZATION.......................................23
Optimization with Rekluse Adjustable Reach Lever........23
MAINTENANCE...................................................................24
Clutch wear......................................................................24
Clutch parts......................................................................24
Basket..............................................................................25
Disk inspection examples ................................................25
NEED ADDITIONAL HELP?................................................26

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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:
•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 bike
with the product.
•Protect eyes and skin –wear safety
glasses and work gloves.
•Drain the oil before removing the clutch cover. If possible,
you can also lay the bike on its side to avoid draining oil.
•Use the torque specifications found in your OE service
manual.
•Oil: 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.
•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 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. Drain the oil or lean the bike on its side.
4. Before removing the clutch cover, be sure to note the
positon of the clutch actuator arm as shown below. This
is critical for adjustment. It may look slightly different
than the image shown below; note the position of the
actuator arm as it appears on your particular bike.
5. Remove the clutch cable from the actuator arm.
6. Remove the OE clutch cover. Set aside. It will be
reused.

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7. Remove the OE pressure plate bolts, springs, pressure
plate, and throw-out.
8. Remove the clutch pack.
OE Pressure plate
springs and bolts
Pressure plate
Throw-out

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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 bike is equipped with these parts,
remove them and set the spring aside. Only some bikes will
reuse the spring. Refer to the Setup Sheet for installation.
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.

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

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•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. Install the Rekluse clutch pack. The clutch pack varies
depending on the bike 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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3. Reinstall the throw-out and pressure plate, then install
the Rekluse pressure plate springs and bolts. If your kit
includes Rekluse screw sleeves or spring bolts, install
them in place of the OE components. If not, resuse the
OE components.
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.
4. Torque the pressure plate bolts in small increments in a
star pattern to OE specifications.
5. Install the clutch cover gasket based on your bike model.
Rekluse
Springs
Bolts
Screw Sleeves

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CLUTCH COVER INSTALLATION
Before securing the clutch cover in place or reattaching the
clutch cable bracket to the engine, follow the next steps to
achieve the correct actuator arm orientation to ensure
adequate cable travel during use.
Note: The clutch actuation mechanism is a rack and pinion
system. Ensure the pinion gear and rack are oriented
correctly when installing the cover.
Actuator shaft
(Pinion gear)
Throw-out
(Rack gear)

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1.Align the teeth on the throw-out with the teeth on the
actuator shaft in the clutch cover. Replace the clutch
cover carefully, ensuring the throw out rod connects with
the actuator shaft.
Note: Yamaha R3 models only: An additional
adjustment is required for the actuator arm on this bike.
Remove the snap ring from the actuator arm and move the
arm one tooth counterclockwise. Reinstall the actuator arm
and then the snap ring.

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2.The actuator arm should be aligned so that when the cable
is reattached the arm is in the position that was noted
before installation.
Note: Ensure it matches the position that was noted on your
bike specifically as it may differ on other bikes.
a.If the actuator arm is in the correct position, continue
with the step 3.
b.If the actuator arm is not in the correct position, gently
pull the cover off and move the actuator shaft one gear
tooth on the throw-out. Replace the clutch cover and
recheck the actuator arm position.
3.When the actuator arm is in the correct positioned, lightly
tighten the cover bolts in a star pattern. Torque the bolts in
small increments before tightening all the bolts to OE
specifications.
4. Reattach the clutch cable to the actuator arm.
5.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.

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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.
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

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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 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,
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 6,000-9,000 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.
f) When the bike returns to idle, rest your hand across
the clutch lever. Rev the engine again to 6,000-9,000
RPM so you can observe the movement while feeling
for Free Play Gain with your hand.

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The Hand Method
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, 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 6,000-9,000 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 returns to idle, rev the engine between
6,000-9,000 RPM a second time to verify the Free Play
Gain again.
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.

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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.
•Clutch lever only
moves slightly or
does not move at
all (too little Free
Play Gain)
•Clutch slips
•Bike 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.