Rekluse Motor Sports - Rekluse Aftermarket Performance Racing

REKLUSE MOTOR SPORTS
The z-Start Pro Clutch
INSTALLATION GUIDE
SUZUKI
RMZ450
LTR450
191-865
Manual Revision: 032508
©2002 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
110 E. 43rd Street
Boise, Idaho 83714
208-426-0659
support@rekluse.com
TABLE OF CONTENTS
2
z-START PRO CROSS-SECTION VIEW
3
INCLUDED PARTS
3
REQUIRED TOOLS
3
BIKE PREPARATION AND DISASSEMBLY
4
CLUTCH BASKET INSPECTION
5
INSTALLING THE z-START PRO CENTER CLUTCH
6
INSTALLING THE CLUTCH PACK
7
INSTALLING THE z-START PRO CLUTCH
8
DETERMINE THE INSTALLED GAP OF THE z-START PRO CLUTCH
11
SETTING CLUTCH CABLE SLACK
13
APPENDIX A – CENTER CLUTCH REMOVAL TIP SHEET
14
z-Start Pro Installation Guide 2
Z-START PRO CROSS-SECTION VIEW
Lever Return
Spring Carrier
Top
Plate
Pressure
Plate
Friction
Disk
Drive
Plate
Retaining
Ring
Rotating Hub
Assembly
Stock Throw-out,
bearing, and washer
Throw-out
Spacer
Lock
Washer
Center
Clutch
INCLUDED PARTS
Item











Top Plate
Pressure Plate
Rekluse Center Clutch
Retaining Ring
(8) RMS Measured Drive Plates
(1) RMS .065‖ Plate (Adjustment
Plate)
Rotating Hub Assembly
External Tab Lock Washer
Lever Return Spring Carrier
Rekluse Throw-out Spacer
Rekluse Throw-out (LTR450
Only)
Item
 (27) 7/16‖ Chrome Steel Ball Bearings
(big bore bikes)
 (3) 7/16‖ Tungsten Carbide Ball
Bearings (LTR 450 Only)
 (10) M4x12 Torx Head Screws
 Wave Springs – See Included Tuning
Chart for your Model
 T-20 Torx Bit
 Blue Loctite 243
 Rekluse Clutch Cover Gasket
 Rekluse Wire Gauges
 Quick Splice
REQUIRED TOOLS
 8mm socket
 10mm socket
 27mm or 30mm socket
(for center clutch nut)
3
 T-20 Torx bit (supplied)
 Impact Wrench
z-Start Pro Installation Guide 3
BIKE PREPARATION AND DISASSEMBLY
1. Disconnect the clutch cable at the clutch
perch.
2. Shut off fuel at petcock. Lay bike on left
side. CAUTION: fuel may drain from
carburetor; to prevent fire hazard, place a
suitable container beneath bike to catch
fuel.
3. Remove clutch cover.
4. Remove bolts and springs from OEM
pressure plate.
5. Remove OEM pressure plate.
6. Remove OEM clutch throw out and set
aside. It will be re-installed.
Note: LTR450 uses the included Rekluse
Throw-out in place of the stock one.
7. Remove the clutch pack (friction disks
and drive plates). Separate the friction
disks from the pack as they will be reinstalled.
Note: The 2-piece clutch boss spring
located at the bottom of the clutch pack
will not be re-installed.
8. Remove the OEM center clutch hub
following the steps outlined in the
vehicle manufacturer’s service manual.
Also, see the center clutch removal tip
sheet (Appendix A) for further
assistance.
9. 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.
CLUTCH BASKET INSPECTION
Note: The following outlines Clutch Basket
Dampener Failure. Some Clutch baskets
will last a season, and some last only
hours. If the dampeners go unchecked
clutch damage will result. After inspecting
basket, continue with the z-Start Pro
installation.
Clutch Basket Dampener Operation
Most OEM Clutches use elastomer
dampeners to protect the clutch from shock
loading applied to the basket by the drive
train and/or engine during normal operating
conditions. The dampeners are located
between the clutch basket body and the
ring gear. The dampeners take up the
slack between the ring gear and clutch
basket so that under normal loading they
rotate as one. Under extreme loading the
dampeners provide a cushion so the ring
gear and basket can float independently
and keep shock loads from being
transferred to the clutch.
As the dampeners wear, the system gains
slack and shock loads start getting
transferred to the clutch. This creates a
hammering effect between the clutch basket
and ring gear. The hammering transfers to
the clutch plates and causes the plates to
wear away at the clutch basket and center
clutch hub. If the dampeners continue to go
unchecked, the hammering progresses until
the clutch fails.
Checking Your Clutch Basket for
Dampener Failure
Prior to installing the z-Start Pro, it is
recommended that you check the condition
of your Clutch Basket and Center Clutch
Hub.
5
An indication of failing clutch basket
dampeners is grooving or notching of the
Clutch Basket Ears—where the tabs of the
friction discs index into the clutch basket.
See the following picture.
Another indication of failing dampeners is
notching of the center clutch hub where
the steel drive plates index to it.
Notching along Clutch
Basket Tangs because
of dampener failure.
Maintaining Clutch Basket Dampeners
Unfortunately the OEM clutch basket does
not provide a means to maintain the
dampeners. After the dampeners wear out,
the clutch basket must be replaced. The
choice is either an OEM clutch basket, or an
aftermarket basket. The advantage of an
aftermarket basket is that the dampeners
are serviceable. Rekluse offers aftermarket
clutch baskets specially designed for greater
performance with the z-Start Pro.
WARNING: Installing the z-Start into a
worn out clutch basket can greatly
reduce clutch performance, and damage
the z-Start Pressure Plate.
z-Start Pro Installation Guide 5
INSTALLING THE Z-START PRO CENTER CLUTCH
10. Install the Rekluse Center Clutch with the OEM thrust washer behind it on top of
the basket.
11. Install the included Rekluse external tab lock washer over the main-shaft on top
of the Rekluse center clutch.
12. Torque the center clutch nut to the specified torque found in the manufacturer’s
service manual.
13. Using a pair of adjustable pliers, bend remaining two tabs of external tab washer
up against the nut to secure it. See photo below.
6
z-Start Pro Installation Guide 6
INSTALLING THE CLUTCH PACK
14. The 8 Rekluse steel drive plates packaged with the Rekluse Center Clutch come
pre-measured and are the 8 steel drive plates you will start with.
Install 1 Rekluse steel drive plate onto the Rekluse Center Clutch.
Note: A Rekluse steel drive plate must be the first clutch plate installed.
15. Install the stock friction disks with a Rekluse steel drive plate between each one.
See following chart:
Warning: Do not install the OEM 2-piece clutch boss spring (located at the
base of the stock center clutch).
Top of Pack
Stock Friction disk
Rekluse Steel Drive Plate
Stock Friction disk
Rekluse Steel Drive Plate
Stock Friction disk
Rekluse Steel Drive Plate
Stock Friction disk
Rekluse Steel Drive Plate
Stock Friction disk
Rekluse Steel Drive Plate
Stock Friction disk
Rekluse Steel Drive Plate
Stock Friction disk
Rekluse Steel Drive Plate
Stock Friction disk
Rekluse Steel Drive Plate
Last Plate In
First Plate In
Bottom of pack
7
z-Start Pro Installation Guide 7
INSTALLING THE Z-START PRO CLUTCH
16. 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.
Cut-outs
Rekluse lower
assembly
Scalloped end of ring correctly
oriented: clockwise in relation to
square end.
Threading retaining ring into groove
17. Using a pair of mechanics gloves (the
edges of the ring can be sharp and may
cut you), install the retaining ring into the
Rekluse Center Clutch ring groove.
You must ensure the retaining ring is
snapped into the groove. Start the square
end of the ring and thread the ring into the
groove as shown, ensuring that the
scalloped end of the ring is clockwise in
relation to the square end.
Use a screwdriver to ensure the ring is
seated by sliding along the ring’s inner
diameter.
WARNING: It is CRITICAL that the
retaining ring is fully seated using a
screwdriver, or clutch damage WILL
occur.
WARNING: Scalloped end of ring MUST
be oriented as shown above-right.
8
z-Start Pro Installation Guide 8
18. LTR450 only (RMZ450 skip to Step 19):
Install the 7/32‖ ball bearing with Rekluse
throw-out on top of the OEM throw-out
rod. The 7/32” ball must be between the
OEM rod and the Rekluse throw-out.
Next place the needle bearing and flat
washer on top of the Rekluse throw-out
followed by the Rekluse spacer and
Spring Carrier.
Rekluse
Spacer
Bearing and
Washer
Ball Spacer
Note: Diagrams are representative.
Your parts may differ slightly.
20. Read the Setup and Tuning Guide to
determine desired spring setting.
21. Install the C150 wave spring on top of
clutch lever return spring carrier.
Rekluse
Spring Carrier
Rekluse
Throw-out
19. RMZ 450 only (LTR 450 skip to Step 20):
Install OEM clutch throw-out
Next place the Rekluse Spacer on top of
the OEM throw-out followed by the
Spring Carrier.
Rekluse
Spacer
Note: RMZ450 customers: the RMZ450
does not have a needle bearing or washer
on it; place throw-out spacer on top of the
stock throw-out.
22. Install the C200 wave spring (if used by
chosen configuration) on top of rotating
hub into the locating pocket.
Rekluse
Spring Carrier
OEM
Throw-out
9
z-Start Pro Installation Guide 9
23. Place a small amount of oil into the
ball grooves of the Rekluse Pressure
Plate.
25. Push and hold the pressure plate down,
overcoming the wave spring(s) so the 10
rotating hub posts index into the 10
pressure plate holes.
24. Away from the bike, install the steel
balls into the pressure plate ball
grooves. Refer to Setup and Tuning
Guide for desired number of balls
and proper distribution pattern.
If your basket has 2 sets of slots,
make sure you index the Rekluse
pressure plate tabs into the
main/deep slots.
Rotating hub posts indexed
into pressure plate holes.
26. 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.
10
z-Start Pro Installation Guide 10
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.
If 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 31.
27. 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 topmost friction disk. If no ―float‖ exists,
top-most steel drive plate has become
disoriented during previous step and
needs to be re-installed.
28. 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.
Use the small leg of
wire gauges.
Try to slide wire gauges
between pressure plate and
pads of top friction disk.
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 31.
29. If the wire gauges slide in smoothly,
the clutch pack needs adjustment.
Swap the thick Rekluse adjustment
drive plate for the top drive plate.
Repeat step 30.
Note: Once the drive plate has been
used and the clutch wears enough so
the wire gauges slide in again, the
friction disks need to be replaced.
11
Attempt to slide both
gauges in 180° apart
simultaneously
z-Start Pro Installation Guide 11
30. Install the remaining 8 torx head
screws using blue Loctite 243 and
torque to 25 in-lbs (2 ft-lbs.).
31. Remove the 2 screws originally
installed without Loctite, apply Loctite
and torque.
32. Re-install the clutch cover with thicker
Rekluse Gasket. Lig htly tighten all of
the cover bolts before full torque is
applied, or you may break the cover.
Warning: Thick Rekluse gasket must
be used or clutch damage will result.
33. Reconnect the clutch cable to the lever
and stand the bike upright.
IMPORTANT: SEE NEXT PAGE
OF INSTRUCTIONS FOR PROPER
CABLE SLACK SETTING
Adjust the cable slack for the z-Start Pro
(SEE NEXT PAGE).
12
z-Start Pro Installation Guide 12
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 requires starting the motor in neutral and revving to a minimum of 4500
RPMs (approximately ½-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 the
engine. While holding a minimum of 4500
RPMs, check for 1/2" (1cm) of play at the
end of the clutch lever before you feel
significant resistance. Adjust cable slack
accordingly using stock cable slack
adjuster(s).
In other words, when revving the engine,
clutch lever free play should feel like stock.
Note: Be sure to review the included
Break-in and Maintenance Guide for
clutch pack wear adjustments.
WARNING: After a 20 minute breakin period, the clutch plates will seat in
and you must re-measure the
Installed Gap to guarantee the
Installed Gap is within the prescribed
range—make drive plate adjustments
if necessary. Clutch break-in remeasurement 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 Pro
clutch.
Tip: Use one finger with light pull
when checking for lever free play. 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.
13
z-Start Pro Installation Guide 13
APPENDIX A – 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:
th
th
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.
14
z-Start Pro Installation Guide 14
Download PDF
Similar pages