Rekluse Motor Sports - Rekluse Aftermarket Performance Racing
Contents
1. h WA hy Tip Place a suitable container beneath the clutch to catch chips as you machine down the stand offs ProStart Installation Guide 6 Remove Lock nut and throw Machine stand offs down until Maintain pressure inst the guide the Rekluse milling tool bottoms plate so that it remains seated against out against the guide plate the clutch hub guaranteeing each stand off is milled down equally 20 Once the 6 stand offs have been milled down 21 Place the Guide Plate back over the clutch hub remove the guide plate and bib being careful not and use the milling tool to make sure that each to let any metal chips get into the clutch If any stand off has been machined down evenly Use a chips get behind the bib and into the clutch vacuum to suck out any metal chips See housing use a vacuum to suck them out See following picture following picture NOTE To revert your bike to stock configuration contact Rekluse or your distributor to get the Return to Stock Kit ProStart Installation Guide 7 CONFIGURING THE CLUTCH PACK 22 Remove the 8 stock steel drive plates steel disks 23 and the top most outermost stock friction disk from the clutch pack and set aside Install the 8 remaining stock friction disks with 1 Rekluse 047 1 2 mm steel drive plate between each one Make sure the first friction disk installed is the Narrow friction plate it has a larger inner diameter which a2. Indexing the milling tool into the previously drilled hole to machine down the boss 39 See below e 07 and 06 Dyna Models Machine bosses down so they are about 375 tall Boss machined down to 375 tall 07 Touring Bikes Note Boss is oval shaped Use milling tool to machine center of boss to 375 then use a rotary tool to machine remainder of boss to 375 e 98 06 Models Machine bosses down so they are 060 tall Sia 424 n n gt gt 22 3 AKA gt Nh gt Boss machined down to 060 tall 40 Remove any chips or shavings from the inside of the primary cover when finished modifying for clearance ProStart Installation Guide 15 FINAL INSTALLATION STEPS 41 42 44 45 46 47 Note Steps 40 42 are for 98 06 customers only 07 and 06 Dyna customers skip to step 43 Following the guidelines in the H D Service Manual 43 Install the Derby cover clutch access cover with the re install the Primary cover Primary chain inspection modified gasket Use 1 of the included 6 mm spacing cover shift lever and foot peg You may need to shims behind both of the bottom 2 screws corresponding replace the primary gasket if it was damaged upon to the 2 modified primary cover bosses The Spacing removal shims ensure that when the screws are tightened they don t interfere with the ProStart See following pictures Modify the Derby Cover Gasket
3. Tab friction disk Using a 4mm hex key line the 6 button head screws up with the 6 stand offs and thread each screw into one of the stand offs a couple of turns Tighten each of the 6 screws down in two steps go around once threading each screw in about halfway then go around threading the screws in the rest of the way Torque each screw to 8 ft lbs See picture at right Tabs of Pressure Plate lined up with the open basket slots Using a 4 mm hex key to keep the screws lined up with the stand offs ProStart Installation Guide 11 DETERMINE THE INSTALLED GAP OF THE PROSTART CLUTCH 33 Measure the installed gap of the z Start using 2 sets of feeler gauges The feeler gauges must be placed between a friction disk and a steel drive plate in the clutch pack 180 apart You should feel a slight resistance but do not force the gauges in Once the gauges are inserted place thumbs on pressure plate directly in line with gauges Press down with thumbs in a rocking motion If pressure plate moves up and down gap is too large See following pictures There is a required gap range for the 2 possible Pressure Plates Check the part located on top of the center circle of the Pressure Plate It will read 112 688 or 112 688A Note It is easiest to slide the feeler gauges in between the top most steel drive plate and the friction disk behind it using a light prying motion to push the friction disk in towards the ce
4. the ProStart Pressure Plate travel up the ball ramps and push against the Top Plate This action forces the Pressure Plate to engage the clutch pack Installation Tips e In order for the ProStart Clutch to perform properly it must be installed properly read each step of this manual to guarantee proper installation e The ProStart Clutch comes assembled and should never be disassembled e Measuring and maintaining the Installed Gap is critical If the Installed Gap is too large the clutch will slip excessively and cause rapid clutch wear If the Installed Gap is too small the clutch will drag and cause engine stall e A pair of calipers is helpful for measuring steel drive plates e In order to install the ProStart Clutch you will need to purchase the install kit RMS263 ProStart Installation Guide 3 BIKE PREPARATION AND DISASSEMBLY 1 Before you begin read these instructions carefully and check to ensure all parts are present Place the motorcycle on a suitable lift in an upright level position 3 4 Following the guidelines in the H D Service Manual drain the Primary chaincase oil Adjust the in line clutch cable adjuster so that it is all the way in See following picture Cable adjuster adjusted all the way in ProStart Installation Guide 4 INSTALLING REKLUSE CLUTCH LEVER RETURN SPRING 5 Remove the clutch lever pin from the perch and lever by removing the retaining ring form the bottom of
5. the engine to a minimum of 2500 RPMs and adjust the clutch cable slack so that there is adequate lever free play because the ProStart is only engaged when the engine is being revved you must rev the engine to set the proper amount of clutch cable slack While the engine is revved adjust the in line cable adjuster out until you can pull the clutch lever in this will guarantee proper cable slack setup See picture at right WARNING Cable slack must be maintained or premature clutch wear will result The engine idle speed affects when the ProStart engages and disengages Higher idle speeds increase clutch drag at low RPMs Engine idle speeds between 900 and 1050 RPM work best If necessary adjust the engine idle speed according to the H D Service Manual Please refer to the ProStart owner s guide for operation break in and maintenance of the ProStart clutch While the engine is revved you need to be able to pull the clutch lever in before it tightens up to ensure proper cable slack ProStart Installation Guide 17
6. REMCO SE KAA h REKLUSE MOTOR SPORTS ProStart Clutch Harley Davidson Big Twin 1998 2009 INSTALLATION GUIDE RMS683 H D Big Twin 195 683 Manual Revision 093010 2006 Rekluse Motor Sports Rekluse Motor Sports Inc 110 E 43 Street Boise Idaho 83714 208 426 0659 support rekluse com REQUIRED TOOLS e ProStart Installation Kit Sold Separately 11 16 wrench 3 16 Hex Key 7 32 Hex Key 5 16 Hex Key 4mm Hex Key Snap Ring Pliers 2 sets of feeler gauges Torque Wrench Blue Loctite 243 oil resistant Safety Glasses Vacuum INCLUDED PARTS FOR THE PROSTART CLUTCH L ProStart Clutch Assembly CO Throw out Spacer 16 x M6 Button Head Screws assembled inside the ProStart Clutch Assembly O 9 x 047 1 2mm Drive plates 13 x 055 1 4mm Drive plates LI Rekluse 12 Tab Friction Disk O Rekluse 6 Tab Friction Disk O Rekluse Clutch Lever Pin 1 Clutch Lever Return Spring O Return Spring Washer 1 10mm Snap Ring O Rekluse Bib 12 x 6mm Washers Not used on 07 Models ProStart Installation Guide 2 RMS 263 INSTALL KIT PURCHASED SEPARATELY O Guide Plate 1 Clutch Standoff milling tool 149 Drill Bit O Primary Cover Milling Tool 9 Drill Bit Clutch Standoff milling Primary Cover milling tool tool Guide Plate BASIC PROSTART CLUTCH OPERATION The ProStart Clutch functions through centrifugal force As engine RPM increases the balls contained in
7. by cutting at least a 5 3 8 hole out of the center of it Not necessary on WARNING Spacing shims must be used behind the models with o ring style gaskets See following bottom 2 Derby Cover screws or clutch damage will picture result 3 SES Aa eee S Derby cover screw with 6mm spacing washer added behind the head Bottom two Derby cover screws installed with one 6mm spacing washer added Following the guidelines in the H D Service Manual re install the Primary cover Primary chain inspection cover shift lever and foot peg You may need to replace the primary gasket if it was damaged upon removal Following the guidelines in the H D Service Manual fill the primary chaincase to the proper level with the proper oil Install the Derby Cover If you have an aftermarket Derby Cover check for interference the OEM Derby Covers are concave dished out on the backside If your aftermarket Derby Cover is flat across the backside it cannot be used Install the In Line Adjuster Sticker at this time as shown at right This alerts any future mechanic that this motorcycle has a Rekluse Pro Start installed and the cable slack needs to be adjusted properly per Rekluse instructions ProStart Installation Guide 16 48 49 50 51 52 Take the motorcycle down off of the lift and ensure the transmission is in neutral Start the motorcycle and allow it to warm up With the motorcycle in neutral rev
8. ccommodates the clutch dampener spring If you removed the clutch dampener spring refer to your service manual for proper installation gt E A 7 4 y CE i T 3 24 Install 1 Rekluse 047 1 2 mm steel drive plate on top of the top stock friction disk followed by the Rekluse 12 Tab friction disk See following picture 25 Install 1 stock 062 1 6 mm steel drive plate on top of the Rekluse 12 Tab Friction disk Then install the Rekluse 6 Tab friction disk the Rekluse 6 Tab friction disk must be at the top of the clutch pack See Chart on Page 9 Note The top most clutch plate must be the Rekluse 6 Tab friction disk ProStart Installation Guide 8 New Clutch Pack Configuration 1 Stock Friction Disk narrow friction disk Innermost disk 1 disk installed Rekluse 047 steel drive plate 2 Stock Friction Disk Rekluse 047 steel drive plate 3 Stock Friction Disk Rekluse 047 steel drive plate 4 Stock Friction Disk Rekluse 047 steel drive plate 5 Stock Friction Disk Rekluse 047 steel drive plate 6 Stock Friction Disk Rekluse 047 steel drive plate 7 Stock Friction Disk Rekluse 047 steel drive plate 8 Stock Friction Disk Rekluse 047 steel drive plate 9 Rekluse 12 Tab Friction Disk Stock 062 steel drive plate 10 Rekluse 6 Tab Friction Disk Outermost disk last disk installed 26 To install the ProStart clutch assembly y
9. e throw out set in the previous step when installing the Lock nut Lock the throw out in position by holding the throw out with a 7 32 hex key and apply moderate torque to the lock nut with an 11 16 end wrench See picture at right ProStart Installation Guide 13 NJ 2 lower derby cover screw bosses interfering with the ProStart 36 Using the included 9 Drill and the existing threaded holes drill the holes through in the bottom 2 Clutch inspection cover screw bosses that are interfering Be careful not to damage the threads for the derby cover screws See picture at right 37 Once the holes have been drilled through you can use the Primary Cover Milling Tool to machine down the 2 bosses The holes you just drilled will allow you to index the tool to the boss es when machining Using the 9 Drill to make through holes in the bottom 2 Screw Bosses Holes drilled in 2 bottom screw bosses RELIEVING THE PRIMARY COVER 35 Place the Primary cover over the case to see where it interferes with the ProStart Clutch See pictures below and right The 2 lower screw bosses that need to be modified ProStart Installation Guide 14 38 Use the included Primary Cover Milling Tool to mill the 2 bottom bosses down e 07 Models and 06 Dyna Mill the bosses down so they are 0 375 tall e 98 06 Models Mill the bosses down so they are 0 06 tall See pictures at right
10. nter of the engine For Pressure Plate Part 112 688 Your installed gap measurement needs to be between 023 584mm and 030 762mm Ideal is 023 For Pressure Plate Part 112 688A Your installed gap measurement needs to be between 028 711mm and 035 89mm Ideal is 028 Use 2 sets of feeler gauges 180 apart to get an accurate measurement Adjustment If the gap is greater than the top of the spec called out for your Pressure Plate Part remove one of the Rekluse 047 1 2mm drive plates in the clutch pack and replace it with a Rekluse 055 1 4mm drive plate For further adjustment exchange a stock 062 1 6mm drive plate with a Rekluse 047 1 2mm drive plate to get the correct measurement Repeat step 32 until measurement is within range Slide the feeler gauge in behind the top steel plate with a light prying motion Press down with thumbs in a rocking motion ProStart Installation Guide 12 ADJUSTING THE CLUTCH THROW OUT 34 Using a 7 32 Hex Key turn the stock throw out clockwise until it seats against the Rekluse throw out spacer and stock throw out rod Next back out the stock throw out by turning it counter clockwise loosening 1 1 2 to 1 3 4 turns Install the stock lock nut onto the exposed threads of the throw out and thread the lock nut up against the ProStart pressure plate Ensure that you do not change the position of th
11. ou will need to rotate the clutch hub so the 6 stand offs line up with the 6 outer basket slots left open by the Rekluse 6 Tab friction disk See following picture ow Er J a Bay T b Stand off lined up with open basket slot from the Rekluse 6 Tab friction disk ProStart Installation Guide 9 INSTALLING THE PROSTART ASSEMBLY 27 See the following picture for part identification ProStart Top Plate ProStart Pressure Plate Throw out Spacer 28 Insert the Rekluse throw out spacer dome end out into the hole in the center of the mainshaft See picture at right 29 Thread the stock throw out into the hole in the ProStart Pressure Plate until there is about 1 2 of threads exposed above the ProStart pressure plate See picture at right Throw out threaded into the ProStart Pressure Plate with Y2 of threads exposed ProStart Installation Guide 10 30 31 32 Apply a small amount of Blue Loctite 243 included to the threads of each of the 6 standoffs Line the heads of the M6 button head screws contained inside the ProStart Assembly with the access holes in the Top Plate of the ProStart Assembly See picture at right Screws lined up with access holes in the ProStart Top Plate Place the ProStart Assembly over the clutch hub and index the 6 outer tabs of the ProStart Pressure Plate with the 6 outer basket slots left open by the Rekluse 6
12. ove the shift lever and foot peg Following the guidelines in the H D Service Manual remove the 6 bolts holding the diaphragm spring retainer diaphragm spring and pressure plate to the clutch hub Using an 11 16 end wrench and a 7 32 hex key remove the stock threaded throw out and lock nut from the pressure plate See picture at right out from the stock pressure plate they will be re used Remove the clutch pack 9 friction disks and 8 drive plates and set aside It is not necessary to remove the damper spring or damper spring seat CLUTCH HUB STAND OFF MODIFICATION 16 17 18 19 Clean the center clutch and 6 clutch hub stand offs with contact cleaner so that any residual oil won t attract metal chips Place the Rekluse Bib over the clutch hub lining up the 6 holes with the 6 clutch hub stand offs Position the bib so it covers the entire primary cavity Slide the Rekluse Guide Plate over the 6 clutch hub stand offs until it bottoms out against the clutch hub and hold it in that position See picture at right Using the Rekluse milling tool with a 3 8 drill machine down each of the 6 clutch hub stand offs until the milling tool bottoms out against the guide plate Maintain pressure against the guide plate so that it is seated at its bottom out point against the clutch hub See following pictures at top of page 7 Bib and Guide Plate slid over the 6 clutch hub stand offs
13. the pin 98 07 ONLY 08 SKIP TO STEP 9 Disconnect the clutch cable from the clutch lever and remove the screw and plastic leaf spring from the back side of the lever Re connect the lever to the clutch cable Guide the long leg of the return spring into the hole left by the screw removed in the previous step See following picture 9 Slide the lever with return spring back into the perch Align the hole through the spring body with the pin hole in the lever Insert the shorter leg of the return spring over the lower perch flange and into the groove of the perch See following picture Center the spring body over the pin hole Snap the short leg of spring over the flange and into the groove in the perch 08 ONLY Guide the long leg of the return spring behind the lever as shown below 10 Slide the Rekluse Lever pin through the lever and spring body 11 Place the Aluminum washer over the underside of the Rekluse Lever Pin and secure with the included retaining ring See following picture Note On some touring models washer will not be used Secure spring with retaining ring ProStart Installation Guide 5 REMOVING THE PRIMARY COVER AND STOCK PRESSURE PLATE 12 13 14 15 Following the guidelines in the H D Service Manual remove the Primary chain inspection cover the clutch inspection derby cover and Primary cover On some models this will require you to rem
Download Pdf Manuals
Related Search