Step-by-Step Guide: Installing Rekluse Clutch on KTM and Husqvarna
Table of Contents:
- Introduction
- Preparing the Bike
- Removing the Clutch Cover
- Removing the Pressure Plate
- Removing the Clutch Pack
- Removing the Center Hub
- Checking and Preparing the Dampers
- Installing the Rekluse Outer Hub
- Installing the Drive Pins
- Installing the Rekluse Tech Plates
- Installing the Friction Plates
- Installing the Rekluse EXP Disk
- Installing the Throw Out
- Installing the Rekluse Lining Plate
- Installing the OEM Slider Ring
- Installing the Belleville Spring
- Installing the Rekluse Pressure Bolts
- Installing the Clutch Cover
- Bleeding the Slave Cylinder
- Adjusting the Clutch
Removing and Installing a Rekluse Clutch: A Step-by-Step Guide
Have you ever wondered how to remove and install a Rekluse clutch on your motorcycle? Look no further! In this guide, we will take you through the entire process, starting from preparing the bike all the way to adjusting the clutch. So, let's get started!
1. Introduction
Installing a Rekluse clutch can greatly improve the performance of your motorcycle's clutch system. The Rekluse clutch offers better control, smoother engagement, and reduces the chances of stalling. However, before you can enjoy these benefits, you need to remove the existing clutch on your bike. In this guide, we will walk you through the step-by-step process of removing the clutch and installing the Rekluse clutch.
2. Preparing the Bike
Before you can begin removing the clutch, it's essential to prepare the bike. Start by laying the bike on its left-hand side, ensuring that you place a container underneath the vent lines to catch any fuel that may spill from the carburetor. This precautionary measure will prevent any mess and potential hazards during the clutch removal process.
3. Removing the Clutch Cover
The first step in removing the clutch is to remove the clutch cover. To do this, start by removing the brake pedal spring and pressing down on the rear brake caliper while pulling down on the rear brake pedal away from the cover. Using a screwdriver or needle-nose pliers, insert it between the frame and the brake adjustment bolt. This will make it easier to remove or loosen the oil fill cap before taking off the cover itself.
4. Removing the Pressure Plate
Once the clutch cover is removed, the next step is to remove the pressure plate. Start by removing the pressure plate ring, spring, and pressure plate. Set aside the slider ring, Belleville spring, and pressure plate ring as they will be reused during the installation process. Now, you can remove the clutch pack, starting with the friction and drive plates. Using dental plates can make this process easier. Alternatively, you can remove the entire clutch pack as one unit.
5. Removing the Center Hub
After removing the pressure plate, it's time to remove the center hub with the clutching gear. You can use an impact gun to remove the center clutch nut. Once the nut is removed, take the inner hub out, making sure to put back the washer. Now, soak the exp disk and frictions in oil. Before reinstalling the inner hub, check the condition of the dampers. Place your thumbs on the embossed parts of the inner hub and rotate it back and forth. If the dampers are tight, they are in working condition. Proceed to remove the inner hub from the hub and remove the dampers if necessary.
6. Checking and Preparing the Dampers
Before installing the Rekluse outer hub, it's crucial to check the condition of the dampers. If the dampers are in working condition, you can reuse them. Install six OEM rubber dampers and the inner hub onto the Rekluse outer hub. Start with the attachment point of the damper against the outer rim of the hub. For 450 FXF and XCF models, use the supplied inner hub instead of the OEM inner hub. This is also an option for other DDS models. If necessary, use a dental pick to separate the dampers while pressing in the inner hub. Install the Rekluse inner hub, followed by the tab washer and the OEM center hub nut. Make sure to tighten the center clutch nut to the specified torque.
7. Installing the Rekluse Outer Hub
Now it's time to install the Rekluse outer hub. Start by seating the drive pins into the Rekluse outer hub. Then, install the first Rekluse tech plate, ensuring the proper orientation is followed. Continue to install the remaining drive plates and friction plates. Once they are all in place, install the Rekluse exp disk and the throw-out. Finally, install the Rekluse lining plate onto the pressure plate and then install it into the center hub. Don't forget to install the OEM slider ring with the rounded portion facing up.
8. Installing the Rekluse Pressure Bolts
With the main components in place, it's time to install the Rekluse pressure bolts. Make sure to tighten the bolts loosely and then use a torque wrench to tighten them to the suggested torque specification. You can use a dental pick to remove the O-ring from the OEM cover and then install the OEM gasket into the Rekluse clutch cover. Finally, install the clutch cover, making sure to use the proper location for each bolt.
9. Bleeding the Slave Cylinder
After the clutch installation is complete, it's necessary to bleed the slave cylinder to ensure proper functionality. To do this, make sure that the clutch reservoir is perpendicular to the ground and use a fluid recommended for the clutch reservoir. Attach a bleed tube to the banjo bolt port and loop it into a suitable container. Pump the clutch lever three to five times and then hold it against the handlebar. Open the bleed port while continuing to hold the clutch lever and tighten the bleed port when pressure is lost. Finally, check the fluid level in the clutch master cylinder and fill if necessary.
10. Adjusting the Clutch
Now that the clutch is installed and bled, it's time to adjust it to find the optimal setting. Using the long end of a 4-millimeter Allen key, turn the adjuster screw clockwise until it stops under moderate pressure. This is the starting point. From here, you can use various methods to check for free play gain. One method is using the rubber band technique, while another method is using your hand to check the free play gain. Adjust the clutch accordingly until you find the correct setting that provides the desired free play gain.
Congratulations! You have successfully removed and installed a Rekluse clutch on your motorcycle. Enjoy the improved performance and control that comes with this upgrade!
Pros:
- Improved clutch control and smoother engagement
- Reduced chances of stalling
- Enhances overall riding experience
Cons:
- Requires proper installation and adjustment for optimal performance
- May take some time and effort to remove and install the clutch
Highlights:
- Learn how to remove and install a Rekluse clutch on your motorcycle
- Step-by-step guide with detailed instructions and tips
- Improve clutch control, smoother engagement, and reduced stalling possibilities
FAQs:
Q: How long does it take to remove and install a Rekluse clutch?
A: The time required can vary depending on your experience and familiarity with the process. It can take anywhere from a couple of hours to a full day.
Q: Do I need any special tools to remove and install a Rekluse clutch?
A: Some specialized tools such as an impact gun and torque wrench may be required. It's recommended to have a basic set of tools for motorcycle maintenance.
Q: Can I install a Rekluse clutch on any motorcycle?
A: Rekluse clutches are available for a wide range of motorcycle models. However, it's essential to ensure compatibility with your specific bike before making a purchase.
Q: Will installing a Rekluse clutch void my motorcycle's warranty?
A: It's always best to check with your motorcycle's manufacturer or dealer to understand the impact on the warranty. In some cases, modifications to the clutch system may affect the warranty.
Q: Can I revert back to the stock clutch after installing a Rekluse clutch?
A: Yes, it is possible to remove the Rekluse clutch and reinstall the stock clutch if desired. However, it is recommended to consult the product manual or seek professional assistance for a smooth transition.
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