Rekluse Motor Sports TCS Clutch Baskets TRX 450R 2004 – 2006
Contents
1. one per pocket To make installing the OEM dampeners easier you will need to form the shims against the ring gear wall so that the shims match the contour See following picture Form Shim to the side of ring gear wall cid F V ten gt j ii i TRA n fi i i ae Pa Lalli H e gt 7 ni ke i DE eal lar hi Ta a se J ie i ne 2 cli 3 IC Note Over time the OEM dampeners shrink causing the fit between the ring gear and basket to loosen leading to clutch hammering and eventually clutch failure The Rekluse shims allow you to adjust the slop created by the shrunk dampeners and eliminate clutch hammering 5 Install the OEM cushions with the proper orientation skinny side to the right when looking at the back of the basket Make sure the shims stay in place while you install the cushions See following pictures Push Cushion in compressing it with your thumbs Proper Cushion orientation Proper Cushion and shim installation 6 Install the included retainer plate with the included M6 screws Tighten to 80 in Ibs 6 6 ft lbs in a criss cross pattern to compress the assembly evenly 7 Using a hammer and punch peen over the ends of the screws where they come through the bottom inside of the clutch basket See following picture 8 Install the new clutch basket assembly into the engine following the procedures in the OEM service manual 9 For z S2. Rekluse Motor Sports TCS Clutch Baskets TRX 450R 2004 2006 Installation Guide Copyright 2006 Rekluse Motor Sports TCS Revision 1 000 RMS 4115 195 4115 Manual Revision 122005 Rekluse Motor Sports Inc 110 E 43 Street Boise Idaho 83714 208 426 0659 support rekluse com Reguired Tools To Assemble Basket 1 4 inch Driver Torgue Wrench Basket verview a T Stock Ring Gear Retaining Plate di E lS ak ae Note Rekluse Shim strips not shown above Included Parts TCS Clutch Basket Core 7 M6 x 1 x 10 Socket Head Screws Retaining Plate M3 Allen Socket 7 x Rekluse Shim Strip www Bike Preparation and Disassembly 1 Following the procedures in the OEM service manual remove the existing clutch basket from the engine Note It is a good idea to replace the side case cover gasket when re installing the basket and clutch 2 Remove the rivets holding the primary ring gear to the OEM aluminum clutch basket The rivets can be removed by milling drilling or grinding the heads off of the ring gear side of the OEM basket See following picture Warning When removing the OEM rivets do not damage the steel ring gear as it will be used with your new Rekluse TCS Clutch Basket 3 Remove all components from the OEM basket taking note of how everything will be reassembled 4 Place the OEM gear recessed side out onto the Rekluse TCS Clutch Basket and install the 7 brass shim strips
3. tart installation refer to the z Start Installation Guide that was included with the z Start Clutch For re installing your stock clutch follow the procedures in the OEM service manual
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