Rekluse RADIUSX User manual

©2015
Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[e-mail]
INSTALLATION GUIDE
For Harley-Davidson Big Twin
Cable Actuated
Doc ID: 191-6203A
Revision: 100219

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Table of Contents
OVERVIEW ...................................................................................2
INSTALLATION TIPS ....................................................................3
TOOLS...........................................................................................3
INCLUDED PARTS .......................................................................4
BEFORE YOU BEGIN...................................................................5
Belleville spring options.............................................................5
DISASSEMBLE CLUTCH..............................................................6
INSTALL THE CLUTCH PACK .....................................................9
Notes for installation..................................................................9
Clutch pack................................................................................9
INSTALL THE PRESSURE PLATE.............................................12
SET THE INSTALLED GAP ........................................................15
PRIMARY COVER INSTALLATION............................................17
RESET THE LEVER FREE PLAY...............................................18
CHECK FREE PLAY GAIN .........................................................19
Learn how to check Free Play Gain ........................................19
Two Ways to Check for Free Play Gain..................................21
The Rubber Band Method.......................................................21
The Hand Method....................................................................23
ADJUST THE INSTALLED GAP .................................................25
BREAK IN THE NEW CLUTCH...................................................26
EXP TUNING OPTIONS .............................................................28
Changing the springs ..............................................................29
LEVER SAFETY STRAPS ..........................................................31
NEED ADDITIONAL HELP?........................................................31
OVERVIEW
This kit replaces the OE (Original Equipment) or “stock” clutch pack.
·This kit will replace all the OE frictions, drive plates, and spring ring
with a Rekluse TorqDrive®clutch pack and EXP disk.
·No modification of the OE parts are necessary.
Do not dyno test this product without reviewing the
included dynamometer document.

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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 the Installation
and User Guide before operating the bike with the product.
·Videos related to this product can be viewed online at
www.rekluse.com/support/videos.
·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.
·Visit www.rekluse.com/support for a full parts fiche illustration and
part numbers.
·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.
TOOLS
·Hex key set –
(Standard SAE)
·T27 Torx bit, and possibly
other Torx sizes
·10 mm socket
·Torque wrench (in-lbs & ft-lbs,
or N-m)
·Open-ended wrenches
(Standard SAE)
·2x dental pick tools

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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
15
31
Spring ring hold down plate
1
63
Steel drive plate - .040” (1 mm) thick
9
68
Steel drive plate - .065” (1.6 mm) thick
1
69.1
TorqDrive
®
friction disks
9
69.2
Damper (judder) spring friction disk - .150”
(3.81 mm)
1
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

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BEFORE YOU BEGIN
·Warm up the bike and check the idle speed before installing
the clutch. The idle speed will determine which EXP springs
to install for the optimal engagement setting. The chart can
be found in the EXP tuning options section.
·Rekluse recommends replacing the chaincase cover gasket
when installing this product.
Belleville spring options
Typically, the OE Belleville spring is reused when installing a
Rekluse auto clutch. However, if the bike has a highly modified
engine, and the OE clutch did not provide enough torque
capacity, alternate springs can be purchased to optimize the
clutch setup.
Clutch Torque Capacity
Max Engine Output
Torque (ft-lb)
Harley
-
Davidson
Spring Part
Number
Spring
Type
Spring
Marking
’96-
’06
Models
(excluding
’06 Dynas)
‘07+ Models
(including
’06 Dynas)
37882-06
Belleville
Blue
86
92
37871-04
Belleville
Yellow
103 110
37807-03
Belleville
Pink
125
133
Harley Screaming
Eagle After
-
market
only: 37951
-98
Belleville
None
138 147
For Trikes: 2013 or earlier, or Conversions:
Rekluse highly recommends purchasing the 37951-98 Screamin’
Eagle spring for best results with this clutch product.
Since trikes are heavier and create more inherent drag than a 2-
wheeler, their clutches are more susceptible to creating excessive

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heat during regular use, and thus may cause premature wear,
slip, or poor performance. Installing a higher-force spring can
significantly improve clutch life and performance by reducing this
heat.
DISASSEMBLE CLUTCH
1.Make sure the bike has cooled before disassembling the clutch.
2.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.
3.Stand the bike up on a suitable bike stand or lift.

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4.On the primary chain case, use a 5/8” wrench to remove the oil
drain plug, then drain the oil.
5.Remove any parts that are attached or blocking the primary
chaincase cover. These may include the left floorboard, foot
peg(s), shift lever, and/or the side stand.
Note: Before removing the shift lever, shift the bike into 5th
gear.
6.Remove the primary chaincase cover.

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7. Remove the following OE parts:
1
Pressure plate bolts
2
Spring ring
3
Belleville spring
4
Pressure plate
5
Clutch pack
6
Damper (judder) spring and seat
Note: Set aside the OE damper (judder) spring, damper seat,
and Belleville spring. They will be reused.
1
2
3
4
5
6

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INSTALL THE CLUTCH PACK
Notes for installation
·When assembling the clutch pack, it is important to line up
the alignment notches on the friction disk tabs. Correct
alignment is critical for optimal performance.
·Some friction disks are marked with a small colored dot. This
mark is used for processing and can be ignored.
Clutch pack
1.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.
Align notches of friction disks

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2.Install ALL the Rekluse basket sleeves into the OE 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: In some models, the sleeves will fit deeper into the
basket than others. This is normal.
3.Install the Rekluse damper (judder) spring fiction disk - .150”
(3.81 mm) into the clutch basket.
4.Reinstall the damper (judder) seat and spring into the basket,
then install one Rekluse thick steel drive plate - .065” (1.6 mm).
Note: Use dental picks can help control the basket sleeves when
installing the clutch pack.
BASKET
TANG
BASKET
SLEEVE
Damper (judder) friction disk
OE Damper (judder) seat and spring
Thick steel
drive plate

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5.Add a Rekluse friction disk followed by a steel drive plate.
Continue to alternate friction disks and drive plates for the
entire clutch pack. Remember to align the notches on the
friction disks when installing the clutch pack.
6.Install the EXP disk on top of the last steel drive plate. Align
the notches on the EXP disk with the notches on the friction
disks.
Note: If your bike’s idle RPM has changed from stock –meaning
that it idles either higher or lower than the stock setting –see the
EXP Tuning Options section to determine the best EXP spring
setting before installing the EXP disk.
Steel drive plates
Friction disks
Total clutch pack:
9 frictions disk and
9 steel drive plates
Friction disk
EXP disk

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INSTALL THE PRESSURE PLATE
1.Fully collapse the in-line cable adjuster so that the cable slack
makes the clutch lever very sloppy at the perch.
Note: Adding cable slack ensures that the cable will not have
excessive stress during the pressure plate adjustment.
EXP disk

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2.Reinstall the OE pressure plate with the throw-out and
adjuster still installed. You will reuse this whole assembly,
including the push-rod and jam nut.
3.Remove the throw-out adjuster jam nut from the center of the
pressure plate using an 11/16” socket.
4.Install the OE Belleville spring and the Rekluse spring ring,
then install the OE pressure plate bolts.

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5.Using a 10 mm socket, torque the pressure plate bolts in a
star pattern to 90-110 in-lbs (10–12.4 N-m).
OE Belleville
spring
OE pressure
plate bolts
Rekluse
spring ring
ng

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SET THE INSTALLED GAP
The installed gap is the separation in the clutch pack created by
adjusting the Rekluse Adjuster Assembly. 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.
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.
1.Use the long end of a hex key to turn the adjuster screw
COUNTERCLOCKWISE until it spins freely with little effort.
2.Gently turn the adjuster screw CLOCKWISE until it stops
under moderate pressure. You are trying to feel for the point
at which it bottoms out and starts to lift the pressure plate
(you will feel an abrupt increase in turning effort). This
position is called your starting point.

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3.From the starting point, turn the adjuster screw 1¼ turn
CLOCKWISE to lift the pressure plate.
Note: The ideal Installed Gap created by 1¼ turn past the
starting point is about .035” (.89 mm). If desired, this can be
measured using feeler gauges.
4.Once the installed gap is set,
reinstall and tighten the adjuster
jam nut. Use a hex key to hold
the adjuster screw while using an
11/16” wrench to tighten the nut.
The hex key will prevent the
adjuster screw from turning while
the nut is tightened.
5.Tighten the nut to OE
specifications.
NOTE: When the bike is fully reassembled, the “Installed Gap”
can be tuned or reset by removing only the derby cover. The
primary cover does not need to be removed for the adjustment.

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PRIMARY COVER INSTALLATION
1.Thoroughly clean the mating surfaces of the primary cover
and the engine case.
2.Reinstall the primary gasket
(or new gasket).
3.Reinstall the primary cover,
then torque the cover bolts to
84-108 in-lbs (9.5-12.2 N-
m).
4.Reinstall the drain bolt, then
torque the drain bolt to 36-60
in-lbs (4-6.8 N-m).
5.With the primary cover installed, use a T-27 Torx bit to
remove the derby cover.
6.Using a funnel, add 1.25 quarts of oil to the primary case
through the derby cover cavity. Use the OE recommended oil
or any quality primary oil.
7.Reinstall the derby cover and torque bolts to 84-108 in lbs.
(9.5-12.2 N-m).

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RESET THE LEVER FREE PLAY
“Lever free play” is essentially the “slack” in the clutch cable
before it starts actuating the clutch. Applying a light finger
pressure will take up this slack.
1.Expand the in-line adjuster until the cable slack is between
1/16” and 1/8” at the lever perch.
2.Install the provided warning sticker on the backside of the
clutch lever, such that it is visible to the rider.

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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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·If there is too much Free Play Gain, the installed gap is too
small.
oThe bike 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.
·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
bike seem like it is losing power.
Lever with “slack”
removed
Lever position
around 4,000 RPM
Free Play Gain
1/8”
-1/4” (3 mm-
6 mm)
lever movement
Pl
t
h
“
l
k
”