REKLUSE MOTOR SPORTS INSTALLATION GUIDE
Contents
1. DD n 4 fe P A A 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 1 Install 3 supplied x rings into the Rekluse Center Clutch as shown below leaving one empty pocket between each x ring Ensure that the x ring is fully seated into the pocket There are six pockets 3 will have x rings and 3 will not Note see anti squeal kit manual for further information Empty slots 6 2 Install the Rekluse Center Clutch with the OEM thrust washer behind it on top of the basket 3 Install the included Rekluse external tab lock washer over the main shaft on top of the Rekluse center clutch 4 Torque the center clutch nut to the specified torque found in the manufacturer s service manual 5 Usinga pair of adjustable pliers bend remaining two2. 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 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
3. 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 torx head screws using blue Loctite 243 and torque to 25 in lbs 2 1 ft Ibs Remove the 2 screws originally installed without Loctite apply Loctite and torque Re install the clutch cover with thicker Rekluse Gasket Lightly tighten all of the cover bolts before full torque is applied or you may break the cover Reconnect the clutch cable to the lever and stand the bike upright IMPORTANT SEE NEXT PAGE OF INSTRUCTIONS FOR PROPER CABLE SLACK SETTING 36 Adjust the cable slack for the z Start Pro SEE NEXT PAGE z Start Pro Installation Guide 11 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 2 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 for
4. tabs of external tab washer up against the nut to secure it See photo below z Start Pro Installation Guide 6 INSTALLING THE CLUTCH PACK 6 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 7 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 Last Plate In 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 First Plate In Bottom of pack z Start Pro Installation Guide 7 INSTALLING THE Z START PRO CLUTCH 17 Insert the 3 small belleville washers 19 Using a pair of mechanics gloves the concave side up into the 3 slots at the top of edges of the ring can be sharp and may cut the center clutch ring Initiate by hand then you install the retaining ring into the use a small s
5. FE kal UL SE LJA KI REKLUSE MOTOR SPORTS The z Start Pro Clutch INSTALLATION GUIDE Suzuki RMZ450 2008 191 864 Manual Revision 061708 2008 Rekluse Motor Sports Rekluse Motor Sports Inc 110 E 43rd Street Boise Idaho 83714 208 426 0659 support rekluse com TABLE OF CONTENTS z START PRO CROSS SECTION VIEW 3 INCLUDED PARTS 3 REOUIRED 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 10 SETTING CLUTCH CABLE SLACK 12 APPENDIX A CENTER CLUTCH REMOVAL TIP SHEET 13 z Start Pro Installation Guide 2 Z START PRO CROSS SECTION VIEW Lever Return Spring Carrier Pressure Plate Friction Disk Drive Plate Retaining Rotating Hub Ring Assembly Stock Throw out bearing and washer Throw out Lock Center Spacer Washer Clutch INCLUDED PARTS Item Item LI Top Plate O 27 7 16 Chrome Steel Ball Bearings O Pressure Plate big bore bikes Rekluse Center Clutch 10 M4x12 Torx Head Screws O Retaining Ring LI Wave Springs See Included Tuning O 8 RMS Measured Drive Plates Chart O 1 RMS 065 Drive Plate O T 20 Torx Bit Adjustment Plate O Blue Loctite 243 L Rotating Hub Assembly O Rekluse Clutch Cover Gasket LI External Tab Lock Washer LI 2 Rekluse Wire Gauges O Lever Return Spring Carrier LI Anti sgue
6. al Kit LI Rekluse Throw out Spacer REQUIRED TOOLS e 8mm socket e l 20 Torx bit Supplied e 10mm socket e Impact Wrench e 2 mm or 30mm socket for center clutch nut z Start Pro Installation Guide 3 BIKE PREPARATION AND DISASSEMBLY 1 Disconnect the clutch cable at the clutch 7 Remove the clutch pack friction disks perch and drive plates Separate the friction disks from the pack as they will be re 2 Shut off fuel at petcock Lay bike on left installed side CAUTION fuel may drain from carburetor to prevent fire hazard place a 8 Remove the OEM center clutch hub suitable container beneath bike to catch following the steps outlined in the fuel vehicle manufacturer s service manual Also see the center clutch removal tip 3 Remove clutch cover sheet Appendix A for further assistance 4 Remove bolts and springs from OEM pressure plate 9 Retain OEM thrust washer located between OEM clutch basket and OEM 5 Remove OEM pressure plate center clutch hub 6 Remove OEM clutch throw out and set NOTE thrust washer may be stuck to aside It will be re installed bottom of OEM center clutch hub z Start Pro Installation Guide 4 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
7. 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 13 z Start Pro Installation Guide 14
8. crewdriver to slide the 3 Rekluse Center Clutch ring groove retaining washers out to limit top drive plate i You must ensure the retaining ring is travel See diagrams below 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 WARNING Scalloped end of ring MUST be oriented as shown below T 5 7 Scalloped end of ring correctly oriented clockwise in relation to sguare end Slide toward outer edge of l ju ie SE x b oN 18 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 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 z Start Pro Installation Guide 8 20 Install OEM clutch throw out with bearing and washer on top into the transmission shaft Ensure the needle bearing and flat thrust washer is placed on top of throw out Note Needle bearing and washer are one piece on the RMZ450 21 Install the Rekluse throw out spacer on top of the throw out 22 install the Rekluse clutch lever return spring carrier on top of Reklu
9. se throw out spacer Rekluse Spring Carrier OEM Throw out with bearing and washer Rekluse Spacer 23 Install the C200 wave spring if used by chosen configuration on top of rotating hub into the locating pocket 24 Place a small amount of oil into the ball grooves of the Rekluse Pressure Plate 25 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 26 If your basket has 2 sets of slots make sure you index the Rekluse pressure plate tabs into the main deep slots 2 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 Rotating hub posts indexed into pressure plate holes 28 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 9 DETERMINE THE INSTALLED GAP OF THE Z START PRO CLUTCH Note Installed gap is measured using a 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 press
10. ure plate and the pads of the top friction disk you need to adjust your installed gap according to step 31 29 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 top most steel drive plate has become disoriented during previous step and needs to be re installed 30 Attempt to slide the legs of the 2 included 040 no go wire gauges included in the anti squeal kit between the Rekluse pressure plate and the Try to slide wire gauges friction pads of the top friction disk 180 between ples Us plate and apart 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 32 NOTE The larger 050 gauges are used for bikes without the anti squeal kit WARNING If larger 050 gauges are used improper Installed Gap will result and clutch damage will occur Attempt to slide both gauges in 180 apart simultaneously z Start Pro Installation Guide 10 31 32 33 34 39 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 The adjustment drive plate is 065 Once the drive plate has
11. ward 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 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 Note Be sure to review the included Break in and Maintenance Guide for clutch pack wear adjustments WARNING After a 20 minute break in 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 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 Pro clutch z Start Pro Installation Guide 12 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
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