Rekluse Auto Clutch Install Guide

We are not going to go into great detail on this install. I'll Just give you a general idea of what to do and some tips. The unit comes with a set of really well written directions with pictures.

Degree of Difficulty: 2

Thanks to the guys at Rekluse for supplying a test kit and cover at no charge. These guys are great and will answer any questions you might have. Just call or email them.

Tools & parts needed: 1) Ratchet, extensions, & sockets 2) Wrenches 3) 2 Sets of Feeler Gauges 4) 4mm Allen Key Socket 5) 3mm Allen 6) Inch Pound Torque Wrench 7) T10 Torx head(included with kit) 8) Grinder 9) Oil Resistant Blue Threadlocker (Loctite p/n 24027)

Step1  You must lean the quad on it's side. The flatter you can get it the better. It makes everything easier. But first drain the trans oil and turn off the gas. (image 1)

Tip Disconnect the brake pedal so that you can access the clutch cover bolts easier.

Step 2 At this point you simply remove the stock clutch, modify it as per the instructions and reinstall it. You will not use the 2 metal clutch spring rings in the clutch pack. Also, the 6 clutch bolts and springs will not be needed anymore.

Tip You can download and print the full install instructions here.

Step 3  The most important part of the install is measuring and adjusting the clutch free play. The instructions state that it should be between .028 and .040 inches. The first two times I did this I adjusted it closer to the .028 mark. It turns out that this tolerance is too tight. I burned out my bottom clutch plate the first ride and the trans was very hot the second time out. So on the third try I went closer to the .040 mark. This has worked for me so far.

Step 4  If you are re-using the stock clutch cover, you need to grind off a tab on the inside of the cover. See the install instructions for more detail. I did not need to do this because I used the Rekluse over sized clutch cover.

Step 5  Install the perch adjuster. See the install instructions for more detail.

Tip  If using the Rekluse over size cover, you must grind the stock kick starter to avoid it contacting the clutch cover. You have the advantage here because the Rekluse install instructions do not note this problem. And of course I went to kick start it after the install and scratched up my nice new clutch cover. See pictures 2,3 & 4 below for the details.

Step 6 You will need to do some fine tuning and adjustments if needed. See the instructions for more details.

Tip You must periodically check your clutch free play by taking off the cover and measuring it with the 2 feeler gauges.

Tip  When you fill your transmission with oil, please keep in mind that there is a "Full" indicator plug next to the fill plug. It is a Phillips head screw. Simply take that screw out and fill the trans until it starts coming out the smaller hole.

If you have any questions or have installed this yourself and have any other tips you may have learned. Let me know by email. jpsteeler1@yahoo.com

To order yours, click on the link below

This site was developed and maintained by Jeff Poole. Honda, TRX450R, Fourtrax, and all other Honda related terms are property of Honda America Corporation.

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