Rekluse TorqDrive Clutch Pack Operation manual

Doc ID: 193-714A
Doc Revision: 030518
READ ME FIRST
BASKET WEAR
The Rekluse TorqDrive clutch employs basket sleeves to protect the basket from wear caused
by the friction disks. With the sleeves, the basket will no longer notch, which may give the
appearance that the basket is not wearing and does not need to be replaced.
Before installation of the basket sleeves, 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.
The basket should also be inspected for any fatigue cracking at the tang bases. Replace
basket if necessary.
DAMPER WEAR
Inspect the clutch basket for damper and/or spring rotational play. Dampers/springs should not
be loose. The rubber dampers in the basket assembly will still wear and will eventually break-
down. This is a normal wear item that is usually evident by notching of the basket from the OE
friction disks. Since the basket sleeves prevent notching, the basket and dampers should be
inspected periodically. This is done best with the basket out of the engine.
To inspect the dampers:
xRemove the basket from the engine, hold the ring gear in one hand and the basket in
the other and twist in opposite directions. The rotational play is sometimes accompanied
by an audible “click” sound when rotating back and forth.
xIf any rotational play can be felt between the basket and the ring gear, the dampers are
worn and either the dampers and/or basket assembly need to be replaced. If worn
dampers are not replaced, accelerated wear can occur to the rest of the clutch.

Doc ID: 193-714A
Doc Revision: 030518
PRESSURE PLATE SPRINGS
The Rekluse TorqDrive clutch comes with two sets of pressure plate springs so the rider can choose to
have either a lighter lever pull or more torque transfer through the clutch. DO NOT use higher force
springs than those included in the kit. Clutch and/or engine damage could occur from higher force
springs which could result in bike damage, injury and/or death.
NEW FRICTION DISK BREAK-IN
Failure to follow the oil screen/filter inspection process after break in could cause motor oil
delivery failure which can result in motor failure, serious injury, or death.
Following the installation of a new set of friction disks, there will be a short break in period during which
the friction disks will wear in somewhat. Following this wear in period, it is vital to inspect the oil screens
and/or oil filter.
xSoak new friction disks in oil for at least 5 minutes
xInstall new friction disks
xRide the bike for an initial period
xInspect the oil screens and/or oil filter, and change oil as necessary
Rotate basket and ring gear in opposite directions to check
for any rotational play in the dampers

©2018
Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[e-mail]
INSTALLATION & USER’S
GUIDE
TorqDrive®Clutch Pack
Doc ID: 191-2847A
Revision: 091020

Pg.
2 Doc ID: 191-2847
A
Doc Rev: 091020
TABLE OF CONTENTS
OVERVIEW ...........................................................................2
INSTALLATION TIPS ............................................................2
TOOLS NEEDED...................................................................3
INCLUDED PARTS ...............................................................4
DISASSEMBLE THE CLUTCH .............................................4
CLUTCH PACK INSTALLATION...........................................6
Notes for clutch pack installation .......................................6
Install Clutch Pack..............................................................9
BREAK-IN............................................................................11
TROUBLESHOOTING.........................................................11
Clutch Drag ......................................................................11
Clutch Slip ........................................................................11
MAINTENANCE...................................................................11
Disk inspection examples ................................................12
NEED ADDITIONAL HELP?................................................15
OVERVIEW
This guide shows you how to replace your OE (Original
Equipment) or “stock” clutch pack with your new Rekluse
TorqDrive®clutch pack. This clutch pack is designed
specifically for your bike. The following parts are replaced:
·OE drive plates
·OE friction disks
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.

Doc ID: 191-2847
A
Doc Rev: 091020
Pg. 3
·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.
·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.
·Use the torque values listed in the instructions. Otherwise,
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.
·This clutch pack is not legal to race with in the AMA
Limited or Stock class.
TOOLS NEEDED
Fluid Catch
Container
8
mm Socket
5 mm
Allen
Torque Wrench
Pick
8 mm
5 mm

Pg.
4 Doc ID: 191-2847
A
Doc Rev: 091020
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.
2. Lay the bike on its left side. Catch any fluids that might
drain into a suitable container.
3. Remove the OE clutch cover. Set aside. It will be
reused.

Doc ID: 191-2847
A
Doc Rev: 091020
Pg. 5
4. Use a 5mm Allen to remove the OE pressure plate bolts
and springs. Set the bolts aside. They will be reused.
5. Remove the OE pressure plate.
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.
OE pressure plate
OE pressure
plate bolts and
cups
Throw-out
OE Spring and
hold
-
down ring

Pg.
6 Doc ID: 191-2847
A
Doc Rev: 091020
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 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.
Do not use the “half slots.” See the following picture for
reference.

Doc ID: 191-2847
A
Doc Rev: 091020
Pg. 7
·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.
Note: If the basket is notched or worn, Rekluse recommends
replacing it with a Rekluse Billet Clutch Basket (available for
most models).

Pg.
8 Doc ID: 191-2847
A
Doc Rev: 091020
·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).

Doc ID: 191-2847
A
Doc Rev: 091020
Pg. 9
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 located at the back of the manual
shows that your bike 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 model. See the Setup Sheet
located at the back of the manual for the proper clutch
pack configuration.
4. Reinstall the pressure plate, OEM spring, hold-down
ring, spring cups, and bolts
Sleeve tabs sit inside the
basket
Install all the
b
asket sleeves

Pg.
10 Doc ID: 191-2847
A
Doc Rev: 091020
The Rekluse TorqDrive® clutch can increase the torque transferred
from the engine to the drivetrain. Do not use higher force pressure
plate springs than those included in the kit. Doing so can cause
accelerated wear and fatigue to components that can lead to
part failure, engine damage, bike or vehicle damage, injury,
and/or loss of life.
5. Torque the pressure plate bolts in small increments in a
star pattern to OE specifications.
6. Install the supplied clutch cover spacing gasket if
included in your kit. If none is supplied, simply reuse
your OEM sealing gasket.Reinstall the clutch cover, then
reinstall the cover bolts.
7. Lightly tightening the cover bolts in a star pattern.
Torque the bolts in small increments in a star pattern
before tightening the bolts to 89 in-lb (10 N-m) per OE
specifications.
OEM Components

Doc ID: 191-2847
A
Doc Rev: 091020
Pg. 11
BREAK-IN
·Break-in will occur over the first 1-2 hours of use,
depending on the rider. During break-in more clutch drag
may occur than normal.
·It is recommended to do an oil change after 1-2 hours of
riding to drain any excess clutch debris that occurred
from break-in.
Note: It is normal for some clutch debris to be produced
during break in. Following break-in, remove and inspect
the OE oil filter. Clean or replace it if necessary. Remove
and inspect any additional oil screens for clutch debris and
clean or replace if necessary.
TROUBLESHOOTING
Clutch Drag:
·Cold Drag Only –If drag occurs only while the bike is
cold, oil is the most likely cause. Be sure to warm up the
bike before riding/racing. Use of new or lighter weight oil
can help to minimize cold drag.
·Hot and Cold Drag –Check for any warped steel drive
plates or frictions in the clutch pack, or other signs of
wear caused by extreme heat.
Clutch Slip:
·If clutch slip occurs, inspect the clutch for signs of wear
or heat.
·Check clutch lever free play.
MAINTENANCE
Rekluse clutches are built using high quality materials but do
wear based on the rider’s use, type of terrain, and natural
wear and tear. Clutch longevity and performance is greatly

Pg.
12 Doc ID: 191-2847
A
Doc Rev: 091020
increased with clean oil and other bike factors that reduce
engine heat.
·Check clutch lever free play.
·Inspect all of your clutch parts at regular maintenance
intervals for signs wear or excessive heat, and replace
components as necessary. Clutch wear is dependent on
the riders use.
·Inspect and replace basket sleeves if they appear to be
notched from friction disks.
·Keep up with regular oil changes as per the bike
manufacturer’s recommendations. Clutch performance
and longevity depend on clean oil.
·For optimal clutch performance Rekluse recommends
using fresh, clean oil that meets JASO-MA oil rating
requirements.
·Repeat the break-in procedure anytime you replace the
friction disks. Always soak friction disks in new oil for at
least 5 minutes before installing.
Disk inspection examples
When inspecting the clutch pack, the following pictures can
be used as a reference. These are best viewed in color by
viewing this install document at
www.rekluse.com/support.

Doc ID: 191-2847
A
Doc Rev: 091020
Pg. 13
Drive Plates –If the clutch pack is getting high amounts
of heat, purple, blue, or black color can be seen on the drive
plate teeth. See pictures below. Not all drive plates look the
same and may look different than pictured.
Normal Heat High Heat Excessive Heat
(Blue) (Black)
Friction Disks –Due to the dark color of the friction
material, the friction disks will appear almost black as soon
as they are put in oil. During inspection, look for glazing of
the friction material. Glazing will appear shiny and feel like
glass, even after oil is cleaned from the friction disk. Not all
friction disks look the same and may look different than
pictured.

Pg.
14 Doc ID: 191-2847
A
Doc Rev: 091020
Normal
Friction
Glazed
Friction

Doc ID: 191-2847
A
Doc Rev: 091020
Pg. 15
NEED ADDITIONAL HELP?
Website
www.rekluse.com/support
Frequently asked questions
www.rekluse.com/faq
Support Videos
www.rekluse.com/support/videos
Phone
[phone]
Technical Support
Contact Technical Support for questions related to product
installation, tuning, and performance.
Hours:
Monday thru Friday: 8:00 a.m. - 5:00 p.m.
Mountain Time zone
Email: [email protected]
Customer Service
Contact Customer Service for additional product information,
orders, and returns.
Hours:
Monday thru Friday: 8:00 a.m. - 5:00 p.m.
Mountain Time zone
Email: [e-mail]

 

 

))
*
6(&7,21))
6&$/(
>PP@0$;
>PP@0,1
'(7$,/*
6&$/(
6(7836+((7
,7(0180%(5
'(6&5,37,21
48$17,7<

%$6.(76/((9(


2(-8''(56($75(86(


2(-8''(5635,1*5(86(


)5,&7,21',6.PP


7254'5,9()5,&7,21',6.PP


67((/'5,9(3/$7(PP


67((/'5,9(3/$7(PP

)5$1./,15' %2,6(,'$+2
:::5(./86(&20
3+ )$;