Rekluse Motor Sports
Contents
1. 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 WARNING Scalloped end of ring MUST be oriented as shown above right Scalloped end of ring correctly oriented clockwise in relation to 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 z Start Pro Installation Guide 6 18 Install OEM clutch throw out 21 Install the C200 wave spring chosen based on your desired setup from the tuning sheet for your bike on top of rotating hub into the locating pocket 19 03 05 RFS and All Husaberg Owners Only Install the Rekluse throw out spacer on top of the throw out 22 Place a small amount of oil into the ball grooves of the Rekluse Pressure Plate 23 Away from the bike install the 7 16 steel balls into the pressure plate ball grooves There are 2 7 slots if you chose a 24 ball configuration leave an empty slot after every 8 ball empty ball grooves must be evenly spaced War2. 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 11
3. FAESHFAL L ESE REKLUSE MOTOR SPORTS The z Start Pro Clutch INSTALLATION GUIDE KTM RFS 03 07 Husaberg Polans 450 525 Outlaw KTM 450 525 XC ATV 191 833 Manual Revision 032508 02002 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 INCLUDED PARTS REQUIRED TOOLS BIKE PREPARATION AND DISASSEMBLY INSTALLING THE z START PRO CENTER CLUTCH INSTALLING THE CLUTCH PACK INSTALLING THE z START PRO CLUTCH DETERMINE THE INSTALLED GAP OF THE z START PRO CLUTCH APPENDIX A CENTER CLUTCH REMOVAL TIP SHEET 11 z Start Pro Installation Guide 2 Z START PRO CROSS SECTION VIEW Wave Plate Spring Pressure Plate Pressure Plate Tab Friction Disk __ R _ _ T a 4 4 ML D Yu NM 199r ann MP we enw ee ee ee I 1 33 EE o ee 2 2222 o so UU OG dr he eM en hh rh Rh reuerti trtttrn Ci eee gt OO Mii m as oa a s a a cc GI COCCO ct ASSOC o eee eee lt a EiERo ROCCO COCCO EET 3 M o OEO M ine ir ee i maar Drive emm Plate Retaining Rotating Hub Stock Throw out Ring Assembly bearing and washer Wave Spring
4. k Locator Center Loc Clutch Washer INCLUDED PARTS Item Item O Top Plate O 27 7 16 Chrome Steel Ball Bearings Pressure Plate O 10 M4x12 Torx Head Screws Rekluse Center Clutch Wave Spring Locator O Retaining Ring O Wave Springs See Tuning Chart O 7 RMS Measured Drive Plates 1 T 20 Torx Bit O 1 RMS 0 060 Drive Plate Adjustment O Blue Loctite 243 Plate O Rekluse Wire Gauges Rotating Hub Assembly O External Tab Lock Washer O Throw out Spacer 03 05 Models Only REQUIRED TOOLS e 8mm socket e 20 Torx bit supplied e 10mm socket e Impact Wrench e 27mm or 30mm socket e 2 Sets of Feeler Gauges optional for center clutch nut z Start Pro Installation Guide 3 BIKE PREPARATION AND DISASSEMBLY NOTE 02 03 models come with 070 friction plates stock Owners of these models must verify thickness of their friction plates if they are 070 they will need to be replaced with 078 04 and newer friction plates Shut off fuel at petcock Lay bike on left side CAUTION fuel may drain from carburetor place a suitable container beneath bike to catch fuel to prevent fire hazard Outlaw KTM ATV Owners Lean the quad against a fixed stationary object at a suitable angle so that the quad is stable the further you lean it over the easier the install will go Place blocks or stands under front and rear wheels to prevent the quad from falling When Quad is tipped on its side be pre
5. luded with z Start Pro Clutch Kit to tighten the Installed Gap Once the 060 drive plate has been used and the clutch wears enough so the wire gauges slide in again the friction disks need to be replaced z Start Pro Installation Guide 9 31 32 Remove the 2 screws originally installed without Loctite apply Loctite and torque He install the clutch cover with the OEM Gasket 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 10 APPENDIX A CENTER CLUTCH REMOVAL TIP SHEET The following covers 3 methods for removing the OEM center clutch from your machine 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
6. ning The Rekluse Throw out Spacer is not used on 06 07 KTM Relea CaS ge an sg Models DO NOT INSTALL IT ON ABER ssa Vn THOSE MODELS Chart for special ball configuration aa yr n lt W _ss instructions 20 Read the Setup and Tuning Guide to Outlaw KTM ATV Owners See Tuning Chart for special ball determine the desired spring setting ASA configuration instructions z Start Pro Installation Guide 7 24 25 Place the Rekluse pressure plate with balls over the lower assembly e Line the 10 holes in the pressure plate up with the 10 rotating hub posts e Line the outer tabs of the pressure plate up with the half moon basket slots NOTE The half moon slots are the basket slots that do not contain the friction disk tabs The half moon slots are where the Rekluse pressure plate tabs must index Push and hold the pressure plate down overcoming the wave spring and hydraulic clutch pressure so the 10 rotating hub posts index into the 10 pressure plate holes E il m 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 of the torx head screws 180 across from one another Lightly tighten the 2 screws Tabs of Pressure Plate indexed into proper basket slots z Start Pro I
7. nstallation Guide 8 DETERMINE THE INSTALLED GAP OF THE Z START PRO CLUTCH 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 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 28 Attempt to slide the shorter legs of the 2 included 0 050 no go wire gauges under the Rekluse Pressure Plate and the top most friction plate 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 Note It is easiest to insert the wires in the space between friction disk pads and then slide them over the top of the pads and up in between the pads and the Rekluse Pressure Plate Wire Gauge between Pressure Plate and friction disk pad then the Installed Gap is good and you can move on to Step 30 Note no go wire gauges will only slide in if the friction disks have Wear Use the small leg of wire gauges 29 If the wire gauges can be slid up and over the pads smoothly the clutch pack needs adjustment Swap the thick 060 Rekluse drive plate for the top drive plate Repeat step 28 30 Install the remaining 8 torx head screws using blue Loctite 243 and torque to 25 in lbs Note A 060 drive plate is inc
8. pared to catch the excess gas and oil in a suitable container to prevent a fire hazard Remove clutch cover Remove bolts and springs from OEM pressure plate WARNING Once pressure plate and springs are removed there will no longer be pressure against the hydraulic system DO NOT pull in clutch lever until z Start Pro is completely installed or slave cylinder housing will be damaged and will need to be replaced Remove OEM pressure plate Hemove OEM clutch throw out and set aside Remove the clutch pack 7 friction disks and 8 drive plates and set aside Remove the OEM center clutch hub following the steps outlined in the vehicle manufacturer s service manual Hetain OEM thrust washer located between OEM clutch basket and OEM center clutch hub NOTE thrust washer may be adhered to bottom of OEM center clutch hub INSTALLING THE Z START PRO CENTER CLUTCH 10 11 12 13 Install the Rekluse Center Clutch with the OEM thrust washer behind it on top of the basket Install the included Rekluse external tab lock washer over the main shaft on top of the Rekluse center clutch Bend middle tab down aligned with flat side of the Rekluse Center Clutch Torque the center clutch nut to the specified torque found in the manufacturer s service manual Using a pair of adjustable pliers bend remaining two tabs of external tab washer up against the nut securing it z Star
9. t Pro Installation Guide 4 INSTALLING THE CLUTCH PACK 14 The 7 Rekluse steel drive plates packaged with the Rekluse Center Clutch come pre measured and are the 7 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 Note With the z Start Pro you use 7 Friction disks and 7 Rekluse Drive Plates NOTE 03 ONLY if you have 070 friction plates we recommend upgrading to KTM OEM 078 friction plates Alternatively you can stack the 060 fine wear steel adjustment plate on top of the 040 steel plate this stacks two steel plates together to achieve installed gap Top of Pack Stock Friction disk Last Plate In Hekluse Steel Drive Plate Stock Friction disk Hekluse Steel Drive Plate Stock Friction disk Hekluse Steel Drive Plate Stock Friction disk Hekluse Steel Drive Plate Stock Friction disk Hekluse Steel Drive Plate Stock Friction disk Hekluse Steel Drive Plate Stock Friction disk Hekluse Steel Drive Plate First Plate In Bottom of pack z Start Pro Installation Guide 5 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
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