Rekluse Motor Sports - Rekluse Aftermarket Performance Racing
Contents
1. when checking for lever free plav This will make it easier to distinguish between the light resistance of the lever return spring and the significant resistance felt when disengaging the Rekluse pressure plate z Start Pro Installation Guide 11 APPENDIX CENTER CLUTCH REMOVAL TIP SHEET The following covers 3 methods for removing the OEM center clutch from your motorcycle or ATV At no time should you ever pry against the standoffs of the OEM center clutch because they are easily broken Note If your bike has an external tab lock washer use a flat blade screwdriver to pry the tabs away from the nut Next use a hammer and punch to lightly tap the tabs flat 1 Pneumatic or electric impact gun Place the bike in gear and remove the nut 2 Clutch Holding Tool Example Motion Pro 08 0008 Use the clutch holding tool to hold the center clutch while using a wrench to remove the center clutch nut 3 Holding the Rear Brake Place the bike in 4 or 5 gear a higher gear gives you more mechanical advantage Apply the rear brake firmly and hold firmly while using a wrench to remove the center clutch nut A second set of hands is helpful z Start Pro Installation Guide 122. REQUIRED TOOLS e 8mm socket e l 20 Torx bit supplied e 10mm socket e Impact Wrench e 27mm or 30mm socket e Snap ring pliers for center clutch nut z Start Pro Installation Guide 3 BIKE PREPARATION AND DISASSEMBLY 12 1 2 Drain oil Remove skid plate if installed Remove rear bolts from bash guard if installed and rotate forward Remove left side footpeg Disconnect header pipe from cylinder head Be careful to retain gasket located between head pipe and cylinder Remove shift lever Remove seat Remove bolt securing oil line under oil tank Place oil suitable container beneath bike Remove oil line banjo bolt from bottom of case Be careful to retain the 2 crush washers as they will be re used Remove clutch actuator arm Remove clutch cover and rotate forward to allow clear access to clutch components You will slightly rotate the oil line towards the rear tire allowing you to pull the side case cover away from the motor 13 14 Remove bolts and springs from OEM pressure plate Remove OEM pressure plate Remove OEM clutch throw out retaining ring with snap ring pliers and set aside Remove OEM clutch throw out from the pressure plate and set aside The snap ring and throw out will be re installed Remove the clutch pack friction disks and drive plates Remove the OEM center clutch hub following the steps outlined in the vehicle manufacturer s service
3. top most steel drive plate has become disoriented during previous step and needs to be re installed 38 Attempt to slide the shorter legs of the 2 included 0 050 no go wire gauges between the Rekluse pressure plate and the friction pads of the top friction disk 180 apart If clutch pack wear exists gauges will slide in with slight resistance Do not force the gauges in if the gauges do not slide in smoothly then the Installed Gap is good and you can move on to Step 40 Use the small leg of wire gauges eee ss gt ji x A Trv to slide wire gauges between pressure plate and pads of top friction disk Attempt to slide both gauges in 180 apart simultaneously NOTE The gauges need to slide in past the relief point on the underside of the pressure plate to get an accurate measurement Pressure Plate Relief Point Gauges go ast relief 1 y day TV A point here z Start Pro Installation Guide 9 39 40 41 42 If the wire gauges slide in smoothly the clutch pack needs adjustment Swap the remaining thicker 0 065 Rekluse drive plate for one of the 0 048 thick drive plates Repeat step 38 Note The adjustment drive plate is 065 Once this drive plate has been used and the clutch wears enough so the wire gauges slide in again the friction disks need to be replaced Install the remaining 8
4. the Rekluse pressure plate tabs into the main deep slots z Start Pro Installation Guide 7 C200 Wave 35 Push and hold the pressure plate down overcoming the wave springs so the 10 rotating hub posts index into the 10 pressure plate holes and line up with the 10 countersunk holes in the top plate Note An extra set of hands is helpful Pressure plate tabs located in main deep basket slots Rotating hub posts indexed into pressure plate holes and lined up with top plate holes 36 While holding down the pressure plate so it is indexed with the basket and 10 rotating hub posts properly place the Rekluse top plate over the Rekluse pressure plate and thread in 2 torx head screws180 across from one another Lightly tighten the 2 screws to secure the Rekluse top plate z Start Pro Installation Guide 8 DETERMINE THE INSTALLED GAP OF THE Z START PRO CLUTCH Note Installed gap is measured using two no go wire gauges Therefore if gauges do not slide between Rekluse pressure plate and the pads of the top friction disk your installed gap is correct lf gauges do slide between the Rekluse pressure plate and the pads of the top friction disk you need to adjust your installed gap according to step 39 37 Verify that top most friction disk moves up and down freely between the Pressure Plate and top most steel drive plate by pulling up and down on top most friction disk If no float exists
5. C7 REKLUSE MOTOR SPORTS The z Start Pro Clutch INSTALLATION GUIDE BMW650 191 600 Manual Revision 121307 2002 Rekluse Motor Sports Rekluse Motor Sports Inc 110 E 43rd Street Boise ldaho 83714 208 426 0659 support rekluse com TABLE OF CONTENTS Z START PRO CROSS SECTION VIEW 3 INCLUDED PARTS 3 REQUIRED TOOLS 3 BIKE PREPARATION AND DISASSEMBLY 4 INSTALLING THE z START PRO CENTER CLUTCH 5 INSTALLING THE CLUTCH PACK 5 INSTALLING THE Z START PRO CLUTCH 6 DETERMINE THE INSTALLED GAP OF THE Z START PRO CLUTCH 9 SETTING CLUTCH CABLE SLACK 11 APPENDIX A CENTER CLUTCH REMOVAL TIP SHEET 12 z Start Pro Installation Guide 2 Z START PRO CROSS SECTION VIEW Rotating Hub Assembly sai n Plate L A A ve Pressure FI Plate Friction IT Disk TA Flat Washer enn Retaining Needle Bearing Ring Flat Washer Stock Throw out i Throw out Spacer INCLUDED PARTS Item Item O Top Plate LI Needle Bearing O Pressure Plate O 2 Flat Thrust Washers Rekluse Center Clutch LI 27 7 16 Chrome Steel Ball Bearings O Retaining Ring L 18 7 16 Tungsten Carbide Ball O 8 RMS Friction Disks Bearings 8 RMS Measured Drive Plates 10 M4x12 Torx Head Screws L 1 RMS 0 065 Drive Plate C200M4 Wave Spring Adjustment Plate O C150M4 Wave Spring O Rotating Hub Assembly T 20 Torx Bit Rekluse Spring Carrier Blue Loctite 243 Rekluse Throw out Spacer O Rekluse Wire Gauges
6. at the scalloped end of the ring is Needle Bearing WARNING Scalloped end of ring MUST be oriented as shown above right z Start Pro Installation Guide 6 27 Install the Rekluse throw out spacer followed by the Rekluse spring carrier on top of the previously installed 30 Install the C200 wave spring on top of rotating hub into the locating pocket bearing and washers r 5 Spring Carri Q CS fe a de b IIA MA i N A 28 Install the C150 Wave Spring top 31 Place a small amount of oil into the the spring carrier C150 Wave 32 29 Guide the Rekluse pressure plate over the throw out and secure with the OEM retaining ring You will need to compress spring to access ring groove 33 34 ball grooves of the Rekluse Pressure Plate Away from the bike install the 18 tungsten carbide TC balls and 9 of the steel balls into the pressure plate ball grooves The TC balls must be evenly spaced amongst the steel balls Pattern 6 TC balls followed by 3 steel balls Repeat until all grooves are full Lean bike over onto stand or with tie down strap Place the Rekluse pressure plate with balls over the lower assembly Line the 10 holes in the pressure plate up with the 10 rotating hub posts Also line the outer tabs of the pressure plate up with the basket slots IMPORTANT The basket has 2 sets of slots make sure you index
7. kluse Friction disk 0 065 Rekluse Steel Drive Plate Rekluse Friction disk 0 065 Rekluse Steel Drive Plate Rekluse Friction disk 0 065 Rekluse Steel Drive Plate First Plate In Bottom of pack z Start Pro Installation Guide 5 INSTALLING THE Z START PRO CLUTCH 23 Place lower assembly into Rekluse center clutch hub You must align the three cut outs in the lower assembly with the corresponding tabs in the center clutch Note some models only have two cut outs BA e gt Scalloped end of ring correctly Cut outs TAN Ga oriented clockwise in relation to Rekluse lower square end assembl 4 4 eL A P ON Threading retaining ring into groove G i KA S TE A te S e Use a screwdriver to ensure the ring is seated by sliding along the ring s 24 Using a pair of mechanics gloves the inner diameter edges of the ring can be sharp and may cut you install the retaining ring 25 Remove the OEM washers etc into the Rekluse Center Clutch ring from OEM throw out groove 26 Install 1 of the flat thrust You must ensure the retaining ring is washers followed by the needle snapped into the groove Start the bearina followed by the square end of the ring and thread the stoi flat aie washer onto ring into the groove as shown ensuring he OEM clinch throw out clockwise in relation to the square end Flat Thrust Washers th
8. manual Retain the OEM Lock washer Also see the center clutch removal tip sheet Appendix A for further assistance Retain OEM thrust washer located between OEM clutch basket and OEM center clutch hub NOTE thrust washer may be stuck to bottom of OEM center clutch hub z Start Pro Installation Guide 4 INSTALLING THE Z START PRO CENTER CLUTCH 18 Install the Rekluse Center Clutch with the OEM thrust washer behind it on top of the basket 19 Install the OEM lock washer on top of the Rekluse Center Clutch 20 Install center clutch nut and torque to the specified torque value found in the manufacturer s service manual 21 Bend washer up against a face of the center clutch nut INSTALLING THE CLUTCH PACK 22 You will use the 8 Rekluse friction disks with 8 Rekluse steel drive plates To start you will use 6 x 0 065 and 2 x 0 048 The top steel drive plate must be a 0 065 Install 1 Rekluse steel drive plate onto the Rekluse Center Clutch Install the Rekluse friction disks with a Rekluse steel drive plate between each one See chart for specific model configuration Top of Pack Rekluse Friction disk Last Plate In 0 065 Rekluse Steel Drive Plate Rekluse Friction disk 0 048 Rekluse Steel Drive Plate Rekluse Friction disk 0 048 Rekluse Steel Drive Plate Rekluse Friction disk 0 065 Rekluse Steel Drive Plate Rekluse Friction disk 0 065 Rekluse Steel Drive Plate Re
9. requires starting the motor in neutral and revving to a minimum of 4500 RPMs approximately i throttle while checking for lever free play There must be clutch lever free play while holding a minimum of 4500 RPMs If there is not enough cable slack the clutch will slip excessively causing the clutch to fail Too much cable slack reduces the ability to disengage the clutch at higher RPMs WARNING Ensure the bike is in neutral or it could lunge forward unexpectedly when revving the engine Place the bike into neutral and start Note Be sure to review the the engine While holding a minimum of included Break in and 4500 RPMs check for 1 2 1cm of play Maintenance Guide for clutch at the end of the clutch lever before you pack wear adjustments feel significant resistance Adjust cable Slack accordingly using stock cable slack WARNING After a 20 minute adjuster s break in period the clutch plates will seat in and you must re In other words when revving the engine measure the Installed Gap to clutch lever free play should feel like guarantee the Installed Gap is stock within the prescribed range make drive plate adjustments if necessary Clutch break in re measurement of the Installed Gap is necessary whenever new clutch plates are installed Refer to the Safety Warnings and Break in Tuning and Maintenance Guide before operating the z Start i Pro clutch Tip Use one finger with light pull
10. torx head screws using blue Loctite 243 and torque to 14 in lbs 1 58 Nm Remove the 2 screws originally installed without Loctite apply Loctite and torque Align the teeth of the clutch throwout at 3 o clock See image below 43 Re install clutch cover 44 45 46 47 48 49 50 51 52 5 54 55 Align clutch actuator arm so it points slightiv past top dead center i e toward rear of bike Rotate forward and connect clutch cable See photo below Clutch Actuator Arm Re install oil line banjo bolt with the 2 OEM crush washers Re install bolt that secures oil line under oil tank Re install shift lever Re install exhaust gasket if it was removed during step 5 Re install exhaust Re install left side footpeg Re install bash plate Re install skid plate Fill oil compartment with oil Refer to OEM manual for recommended volume Stand the bike upright and reconnect the clutch cable to the lever IMPORTANT SEE NEXT PAGE OF INSTRUCTIONS FOR PROPER CABLE SLACK SETTING Adjust the cable slack for the z Start Pro SEE NEXT PAGE z Start Pro Installation Guide 10 SETTING CLUTCH CABLE SLACK IMPORTANT Cable slack adjustment is critical The cable slack must be adjusted properly and maintained frequently Failure to do so will result in clutch failure Adjusting cable slack is different with a z Start Pro Clutch installed Cable slack adjustment
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