Rekluse Motor Sports The e-Axle 2002+ Honda 2000
Contents
1. fist hole is not supported by the stock axle and after a few tightening cycles the fork fist hole will deform To solve this use some emery cloth and lightly sand the outer portion of the hole until the 20 mm Flanged Bushing slides in smoothly See following picture Remove the stock wheel spacers from both sides of the wheel hub Use a clean rag to remove all dirt and sand inside the wheel and install both of the Rekluse wheel spacers After installing the Rekluse wheel spacers stow the wheel in a Suitable place so that the brake rotor cannot be damaged See following picture Note On all models except the Yamahas the disk side wheel spacer is the longer of the two On the 00 02 KTM the wheel spacers are identical unless you will be installing the odometer replacement spacer i i Pe a 6 Coat the center axle in a thin layer of grease to aid installing the axle Note Coat the center axle in a thin layer of grease every time it is re installed after removing the front wheel for tire maintenance 7 Position the front wheel back in between the forks so that the brake disk Is In place between the brake pads and so the wheel spacers line up with the hole in the fork fists 8 Slide the e Axle sub assembly through the right side fork fist and through the wheel spacers in the front hub Rotate the 25 mm bushing so the set screw is facing up this will line the O Offset Mark with the fork fist pinch clamp slot Continue2. sliding the axle through until the 25 mm bushing is almost flush with the outer edge of the right fork fist See following picture Slide the 20 mm Flange Bushing onto the left end of the Center Axle through the left fork fist by positioning the bushing with the set screw facing up this will allow the bushing to slide over the end of the center axle with the set screw indexing against the flat on the left end of the axle Slide the 20 mm bushing in until the flange is flush against the outer edge of the left fork fist See following picture Warning The set screw in the 20 mm Flange Bushing must index onto the axle flat to insure proper installation and function Note You may need to rock the wheel back up and down to get the 20 mm bushing to slide over the end of the center axle and through the left fork fist j E 7 Set screw lined up to i index on the axle flat gm Ad Le h Moderately tighten the 2 left side fork fist pinch clamp bolts to secure the 20 mm Flange Bushing Apply medium strength thread locker to the M8 Hex Flange bolt and install it into the left end of the center axle and torque to 18 foot pounds 24 newton meters Tighten the 2 left side fork fist pinch clamp bolts to the torque values recommended in the service manual 13 With the bike on the ground compress the forks several times by pushing down on the handlebars to allow the right side fork fist to come into proper alignment on
3. the 25 mm bushing Tighten the 2 right side fork fist pinch clamp bolts to the torque values recommended in the service manual Warning If the fork fist pinch clamp bolts are not tightened properly they could come loose allowing the axle to rotate unexpectedly causing severe damage or injury Adjusting the e Axle 1 Loosen the M8 hex flange bolt on the left side of the e Axle 2 Loosen both right and left side fork fist pinch clamp bolts 3 Rotate the e Axle from the right side using a 10 mm wrench on the two machined flats in the 25 mm non disk side Bushing or use a 4mm hex Key through the hole in the M8 Socket Head screw to rotate the e Axle to the desired offset Always rotate the axle clockwise when adjusting the e Axle See following picture Note See next page for information on indicating marks In general negative settings tend to increase steering effort increase front wheel traction and improve straight line stability Positive settings tend to reduce steering effort decrease front wheel traction and reduce straight line stability Other factors such as ground conditions suspension settings tire selection and rider preference will also influence the proper offset setting Try several different offset settings for every riding condition you encounter You will probably find there is no perfect offset for your bike but instead a preferred offset for the type of riding and the type of dirt you are riding on See
4. Rekluse Motor Sports The e Axle 2002 Honda 2000 2002 KTMs 2004 Kawasaki KXs 2004 Suzuki RMZ 250 2002 Yamaha YZs Installation Guide Copyright 2006 Rekluse Motor Sports e Axle Revision 1 000 RMS 2710A 2731A 2741A 2770A 195 2710A Manual Revision 042406 Rekluse Motor Sports INC 110 E 439 Street Boise Idaho 83714 208 426 0659 support rekluse com Required Tools 10mm socket Needle Nose Pliers Wrench to remove stock axle Flat Blade Screw Driver 4 mm or 6 mm Allen Ke e Axle Overview vedi teeta Set Screw Do not Remove 25 mim bushing Center Axle 25 mm Bushing Do not Remove i fl Set Screw Do not Remove e Axle Pull Hole Washer Right Side Wheel Spacer Left Side Wheel Spacer M Hex Flange Bolt 20 mm Flange Bushing Warning The 2 set screws in each bushing are installed by Rekluse and should NEVER be removed or tightened Note This manual refers to right and left as you would be sitting on the motorcycle Warning The e Axle is designed to work with the OEM rotor pads and caliper If you are using a larger diameter aftermarket rotor you will need to check for interference between the rotor and caliper through the range of adjustment the e Axle offers Included Parts for the e Axle e Axle Sub Assembl Left Side Wheel Spacer 20 mm Bushing M8 Hex Flange Bolt Right Side Wheel Spacer Basic e Axle Function The e Axle is an eccentric front axle that allows the rider to easi
5. ace Coil spring located properly Za 7 a u A soe 15 Re install the caliper pin to secu re the brake pads See following picture A alll Coil Spring on the pin and a ns in between the brake pads 12 e Axle Instructions for 00 02 KTM motorcycles This manual supplement is to be used along with the e Axle Install Manual 195 2 10 to install the e Axle on your 00 02 KTM motorcycle 00 02 KTM On models that have KTM analog Odometers typically EXC models you will need to remove the odometer and install the included Rekluse Odometer Replacement Wheel Spacer into the right side of the wheel hub in place of the odometer housing The smaller Rekluse wheel spacer will not be used on the right side of the hub For KTM motorcycles without the Odometer use the 2 regular Rekluse Wheel Spacers See following pictures 13 e Axle Instructions for 02 04 Yamaha motorcycles This manual supplement is to be used along with the e Axle Install Manual 195 2 10 to install the e Axle on your 02 04 Yamaha motorcycle 1 02 04 Yamaha owners only To accommodate the brake line shield that attaches to the lower fork leg you will need to install the included e Axle Spacer and longer M8 x 35mm hex head bolt into the 20 mm Flange Bushing end left end of the axle Be sure to torque the M8 axle end bolt to 18 ft lbs as specified in Step 11 of the e Axle Installation Guide 195 2710 See following pi
6. ctures Installing Spacer Longer M8 bolt stock brake line cover and stock washer into the 20 mm Flange Bushing end of the axle 2 To adjust the e Axle simply loosen the M8 x 35mm bolt and the fork fist pinch clamp bolts Then rotate the e Axle from the right side using the indicator marks on the 25 mm Bushing to set the e Axle at the desired offset 14
7. following pictures Picture showing Max Negative Offset brk Fist Pinch Clamp Axle Bushing Maximum Negative Offset Position Lower Fork Leg d oo Pinch Clamp Slot Align Offset Marks To This Slot Axle Bolt Offset Mark Fork Fist Pinch Clamp Picture showing 0 Offset 0 Offset Position Same as Stock Lower Fork Leg Pinch Clamp Slot Axle Bushing Align Offset Marks To This Slot Axle Bolt Offset Mark Picture showing Max Positive Offset Fork Fist Pinch Clamp Offset Mark Maximum Positive Offset Position Lower Fork Leg Pinch Clamp Slot Align Offset Marks To This Slot Axle Bushing Axle Bolt Re tighten the left side fork fist pinch clamp bolts to the proper torque specification Torque the M8 hex flange bolt on the left side of the e Axle to 18 foot ponds 24 newton meters 6 Compress the forks several times by pushing down on the handlebars to allow the right side fork fist to come into proper alignment Tighten the 2 right side fork fist pinch clamp bolts to the torque values recommended in the service manual Note When the axle is adjusted to the max negative position it is possible to introduce slight interference between the rotor and the leaf spring in the back of the caliper On most models there is usually no interference and if there is it is generally slight and will self clear If your leaf spring rubs the rotor when the e Axle is adjusted all the
8. ly adjust the front wheel trail Changing the front wheel trail affects the handling characteristics of the motorcycle Note All 02 04 Yamaha owners and 00 02 KTM owners please see the end of this manual for added instructions to install the e Axle Bike Preparation and Disassembly 1 Place the motorcycle on a suitable stand so the front tire is no longer touching the ground 2 Refer to your Owners Manual and remove the stock front axle and front wheel Using a clean shop rag remove all dirt and sand from the fork fists and from inside the wheel hub Dirt and sand will mar the surface of your e Axle parts Stow the wheel in a suitable place so that the brake rotor cannot be damaged 3 Disassemble the e Axle Remove the M8 hex flange bolt from the end of the 20 mm flange bushing of the e Axle Slide the 20 mm flange bushing off of the e Axle sub assembly followed by the left side and right side wheel spacers See the following picture Warning The M8 set screws in each bushing are installed by Rekluse and should NEVER be removed or adjusted The e Axle Sub Assembly consisting of the 25 mm bushing and the center axle are assembled by Rekluse and should NEVER be disassembled 3 e Axle Installation Slide the 20 mm Flanged Bushing into the disk side fork fist to check fitment The 20 mm Flanged Bushing should slide into the fork fist easily On some bikes the bushing may not slide in easily because the outer edge of the fork
9. way in you can remove it and replace with the included coil spring See the Coil Spring Installation section at the end of this manual Axle Removal 7 Place the motorcycle on a suitable stand 8 Using a 10 mm wrench remove the M8 hex flange bolt on the left side of the e Axle 9 Loosen both right and left side fork fist pinch clamp bolts 10 Slide a suitable pulling tool screw driver 4 mm hex key etc through the holes in the right end 25 mm bushing end axle And pull the e Axle out See following picture F w an i ims f i s Y a cE gt af F 4 r q 4 S r Kag hy x ay Phy Note Removing the left side axle bushing 20 mm Flange Bushing from the left side fork fist clamp may allow the axle to slide out easier Note Clean all parts before re installing and coat the axle with a thin layer of grease 10 Coil Spring Installation 11 If the leaf spring in the back of the caliper is interfering with your rotor follow the following steps to remove it and replace it with the Rekluse coil spring 12 Remove the brake pads from the caliper by removing the pin 13 Remove the leaf spring from the caliper See following picture 1 14 Re install the brake pads with the included coil spring positioned between them and centered on the holes that the pin slides through securing them Squeezing pads together and sliding up into the caliper with the coil spring in pl
Download Pdf Manuals
Related Search