Rekluse z-Start Pro Clutch
Contents
1. CN i NE 3 kk A i KA 19 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 WARNING Scalloped end of ring MUST be oriented as shown above right Scalloped end of ring correctly oriented clockwise in relation to _ square end T Threading retaining ring into groove Use a screwdriver to ensure the ring is seated by sliding along the ring s inner diameter 20 Remove the OEM Belleville washer from OEM throw out leaving the OEM spacer OEM Throw out Spacer z Start Pro Installation Guide 6 21 Install 1 of the flat thrust washers 24 Install the C200 wave spring on top followed by the needle bearing followed of rotating hub into the locating by the remaining flat thrust washer on pocket top of the OEM clutch throw out and B spacer ATT Spring A KS kal Flat Thrust AB NAM Washers Needle ia SE Bearing TN VF e IX 1 C s V i ea lisa jie N O1 22 Install the Rekluse spring carrier Place a small amount of oil into the followed by the C150 Wave Spring ball groove2. clutch nut A second set of hands is helpful z Start Pro Installation Guide 12
3. 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 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 pr
4. 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 y day TV A Pesi point here z Start Pro Installation Guide 9 32 If the wire gauges slide in 37 Align clutch actuator arm so it smoothly the clutch pack needs adjustment Swap the thick Rekluse adjustment drive plate for the top drive plate Repeat step 31 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 33 Install the remaining 8 torx head screws using blue Loctite 243 and torque to 14 in lbs 1 58 Nm 34 Remove the 2 screws originally installed without Loctite apply 38 Loctite and torque 39 35 Align the teeth of the clutch throwout at 2 o clock See image below 36 Re install clutch cover 40 41 points slightiv past top dead center i e toward rear of bike Rotate forward and connect clutch cable See photo below Actuator Arm Re install shift lever Re install exhaust gasket if it was removed during step 5 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
5. 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 32 30 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 31 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 33 Use the small leg of wire gauges eee ss e X A SE Try to slide wire gauges between pressure plate and pads of top friction disk Attempt to slide both gauges in
6. AW REKLUSE MOTOR SPORTS The z Start Pro Clutch INSTALLATION GUIDE 07 08 BMW650 X Models 191 601 Manual Revision 121207 2002 Rekluse Motor Sports Rekluse Motor Sports Inc 110 E 48rd Street Boise Idaho 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 Friction Disk Drive Plate Flat Washer Retaining Needle Bearing Ring Flat Washer INCLUDED PARTS Stock Throw out Pressure Plate Center Clutch OEM Throw out AA Spacer II I item g U U D D U U U Top Plate Pressure Plate Rekluse Center Clutch Retaining Ring 1 RMS Friction Disks 8 RMS Measured Drive Plates 1 RMS 0 065 Drive Plate Adjustment Plate Rotating Hub Assembiv Rekluse Spring Carrier REQUIRED TOOLS item OOOOOO OOOO Needle Bearing 2 Flat Thrust Washers 27 7 16 Chrome Steel Ball Bearings 18 7 16 Tungsten Carbide Ball Bearings 10 M4x12 Torx Head Screws C200M4 Wave Spring C150M4 Wave Spring T 20 Torx Bit Blue Loctite 243 Rekluse W
7. escribed 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 N Guide before operating the z Start i Pro clutch Tip Use one finger with light pull 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 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 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
8. ire Gauges e 8mm socket e 10mm socket e 27mm or 30mm socket for center clutch nut e l 20 Torx bit Supplied e Impact Wrench e Snap ring pliers z Start Pro Installation Guide 3 BIKE PREPARATION AND DISASSEMBLY 1 Disconnect the clutch cable at the clutch perch Lay bike on right side CAUTION fuel may drain to prevent fire hazard place a suitable container beneath bike to catch fuel Remove shift lever Remove clutch actuator arm Remove clutch cover 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 9 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 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 12 Install the Rekluse Center Clutch with the OEM thrust washer behind it on top of the basket 13 Install the OEM lock washer on t
9. op of the Rekluse Center Clutch 14 Install center clutch nut and torque to the specified torque value found in the manufacturer s service manual 15 Bend washer up against a face of the center clutch nut INSTALLING THE CLUTCH PACK 16 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 17 Youwill use the Rekluse friction disk with the 7 OEM friction disks Install 1 Rekluse steel drive plate onto the Rekluse Center Clutch As you install the rest of the clutch pack place the Rekluse friction disk somewhere near the middle of the pack See chart for specific model configuration Top of Pack OEM Friction disk Last Plate In Rekluse Steel Drive Plate OEM Friction disk Rekluse Steel Drive Plate OEM Friction disk Rekluse Steel Drive Plate Rekluse Friction disk Rekluse Steel Drive Plate OEM Friction disk Rekluse Steel Drive Plate OEM Friction disk Rekluse Steel Drive Plate OEM Friction disk Rekluse Steel Drive Plate OEM Friction disk Rekluse Steel Drive Plate First Plate In Bottom of pack z Start Pro Installation Guide 5 INSTALLING THE Z START PRO CLUTCH 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 Rekluse lower Lo assembl d FRI
10. s of the Rekluse Pressure Plate C150 Wave Spring 26 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 23 Guide the Rekluse pressure plate over the throw out and secure with the OEM 27 Place the Rekluse pressure plate retaining ring You will need to with balls over the lower compress spring to access ring groove 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 the Rekluse pressure plate tabs into the main deep slots z Start Pro Installation Guide 7 28 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 29 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
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