Rekluse Motor Sports EXP Operation manual

©2015 RekluseMotorSports,Inc.
12000W FranklinRd
Boise,Idaho83709
208-426-0659
[e-mail]
REKLUSE MOTOR SPORTS
TheRekluseEXPKit forKTM690 &Husqvarna701-LC4
INSTALLATION &
USER’S GUIDE
Doc ID: 191-6380A
Doc Rev: 070716
OVERVIEW
For MY2016 bike owners only: Refer to the Slave Cylinder Appendix document before installing the
Rekluse-provided slave cylinder on your bike. It may be necessary to change the fluid seals.
This kit replaces the OEM clutch pack with a Rekluse-designed clutch pack designed for optimal
operation specific to your bike.
INSIDE THIS DOCUMENT
oDISASSEMBLY
oINSTALLATION
oSETTING THE INSTALLED GAP & BREAK-IN
oTROUBLESHOOTING
oEXP TUNING OPTIONS & ENGAGEMENT SETTINGS
oMAINTENANCE
INSTALLATION TIPS
Watch the “EXP Auto-Clutch Installation Video”by following this QR code or visiting
rekluse.com/support/videos.
Read this entire document before performing any steps, so you will know what to expect.
Be sure to wear proper eye protection.
It is recommended to replace the clutch cover gasket any time the clutch cover is removed.
Laying the bike on its side allows for easy clutch access and eliminates the need to drain oil
Use clean, quality JASO MA certified oil for motorcycle transmissions for best performance.
When reinstalling components, use the torque specifications found in your OEM service manual
TOOLS NEEDED
Metric socket set
4mm Allen key Torque wrench (in-lb & ft-lb, or N-m) Metric open-end wrench set

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INCLUDED PARTS
Item
Item Type
Qty
13
EXP Base *
2
47
Assembly Screws (temporary, to aid assembly only)
2
51
Fastener - 1/4-Turn Pin *
6
60.1
EXP Adjustment Spring * ( see EXP tuning options)
6
60.2
Pressure Plate Spring (stiffer than stock)
4
63
Drive Plate (.040” [1.0mm] thick)
4
65
Drive Plate (.048” [1.2mm] thick)
3
69
™ Friction Disk
7
70
Basket Lining Sleeve
12
85
Wedge Assembly *
6
86
Slave Cylinder Assembly
1
* Denotes parts assembled as part of EXP disk assembly.
Visit Rekluse.com/support for a full parts fiche illustration
and a listing of all part numbers specific to your product.
ASSEMBLY OVERVIEW

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PREP & DISASSEMBLY
1. Soak the EXP disk and Rekluse friction disks in
engine oil for at least 5 minutes.
2. To avoid draining the oil, lay the motorcycle on
its left side. Alternatively, you can stand the bike
vertically on a center stand and drain the oil.
3. Remove the right side swingarm bolt, and move
the foot peg assembly out of the way of the
clutch cover bolts and clutch cover.
4. Remove the oil filter cover from the engine and
move it up out of the way.
5. Remove the clutch cover bolts and clutch cover,
taking care to not damage the cover gasket.
Replace this gasket if it is torn or damaged.
6. Remove the OEM screws and springs, followed
by the pressure plate and throwout.
7. Remove the outer hub and the entire OEM
clutch pack (all clutch plates).
None of the OEM clutch plates will be reused
with this kit.

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8. Remove the judder spring and the spring seat
washer from the outer hub and set them aside.
These two parts will not be reused with the EXP
clutch pack.
WARNING: It is critical that both the judder
spring (cupped ring) and its seat washer (flat ring)
are removed from the outer hub! Often, the
spring seat washer will be stuck via an oil film to
the outer hub flange.
These two parts will not be reused with the EXP
clutch pack.
Failure to remove both of these parts before
installing the Rekluse clutch plates will result in
poor performance or clutch malfunction.
9. Remove the inner hub from the engine by
loosening the center nut and washer.
HUB REASSEMBLY
NOTE: Because this bike has a slipper clutch with
a “backwards” design, you will assemble the
clutch pack between the two hubs before placing
this assembly into the bike.
1. Place the outer hub on a clean workbench,
then install the oil-soaked clutch pack starting
with a Rekluse friction disk [#69], followed by a
Rekluse drive plate [#63]. Follow this
alternating pattern until all the supplied clutch
plates are installed.
Be sure to align the tabs on the friction disks
with each other. This will make placement into
the basket much easier later.
Last in will be the EXP disk. The EXP disk is
unidirectional and can be installed in any
orientation.

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2. Place the 4x OEM hub springs in their pockets
in the outer hub, then install the inner hub,
taking care to align the arrows of the two hubs.
3. With your hands, compress this assembly
together and flip it over so that none of the
plates become unindexed from the outer hub.
4. Using a 4mm Allen key, thread the 2x provided
assembly screws [#47] through opposing spring
pockets. Tighten just until the springs are
compressed enough to contain the clutch pack,
but not fully clamping the clutch pack.
Do not over-tighten!
This step is designed to make it easier to drop
the assembly into the bike as one unit.
INSTALLATION
1. Install the 12x Basket Sleeves [#70] into the
tang slots of the basket, pushing them down in
until they contact the bottom of the basket.
When properly installed, they will be nearly
flush with the top of the basket.
2. Check to ensure that the 3-piece thrust washer
assembly is correctly in place on the mainshaft.
These may have moved when the hubs were
removed from the bike.
CROSS-SECTION VIEW

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3. Install the hub assembly into the clutch basket,
making sure that all of the friction disk tabs
index into the steel basket sleeves and the
inner hub spline indexes correctly to the
mainshaft.
NOTE: Use only the full tang slots.
Never install any disks into the half-slots.
4. Reinstall the OEM washer and center nut,
applying Loctite© 243 or equivalent thread-
locking compound to the threads.
Use a torque wrench to tighten the center nut to
74 ft-lb (100 N-m), but do not over-torque!
This may require placing the transmission in the
highest gear and having a friend hold the brake
pedal to keep the clutch from spinning.
WARNING: Do not over-torque the center nut!
Over-torqueing will cause drag and can damage
your engine’s bearings or transmission
components.
5. Reinstall the OEM throwout and pressure plate,
followed by the springs [#60.2] and OEM bolts.
NOTE: The Rekluse-provided pressure plate
springs (white) are stiffer than the OEM springs,
and they have been found to significantly help
improve overall clutch performance in the form
of positive engagement and hookup. It is
recommended to install them at this time.
Due to the light nature of the clutch lever with
the stock springs, the stiffer springs should not
adversely affect the clutch lever effort or feel.
Torque the spring bolts to 4.4 ft-lb (6 N-m).
6. With the clutch installed, you can now remove
the screws that were used to hold the assembly
together during installation.
7. Reinstall the clutch cover and oil filter cover,
torqueing the bolts to the OEM spec:
Clutch Cover Bolts: 7.4 ft-lb (10 N-m)
Oil Filter Cover Bolts: 4.4 ft-lb (6 N-m)
8. Reinstall the foot peg assembly and swingarm
bolt, applying thread-locking compound to the
swingarm bolt and torqueing to 59ft-lb (80N-m).

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SLAVE CYLINDER
INSTALLATION
Handle with care! During assembly there is a small
ball bearing [#56] installed in the slave piston
[#28.3] with a small amount of grease. When
installing the Rekluse slave cylinder, make sure the
ball does not come loose.
1. Stand the bike up and lean it on its kickstand or
place it on a suitable bike stand.
2. Remove the plastic chain guard that covers the
slave cylinder.
IMPORTANT CLUTCH FLUID NOTE:
For MY2016 bike owners only:
Refer to the Slave Cylinder Appendix
document before installing the Rekluse-
provided slave cylinder on your bike. It may be
necessary to change the fluid seals in the
cylinder housing and piston.
For all other model-years:
Read the fluid information located on the
reservoir cap of your bike’s clutch master
cylinder. This will inform you of which clutch
fluid to use in the following steps, either mineral
oil or DOT brake fluid.
Generally:
- MY2015 and older: uses mineral oil
- MY2016 and newer: uses brake fluid
Adjustable Slave Cylinder Access:
To ensure access to the adjuster screw on the new
Rekluse slave cylinder, there are 3 options:
1. Modify the OEM plastic chain guard by
drilling a small hole.
2. Purchase an aftermarket chain guard which
allows access to the adjuster screw.
3. Remove the OEM chain guard when making
adjustments (however, the guard must be
securely in place to start the engine or it will
leak oil).

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3. To modify the OEM plastic guard, follow these
steps. If performed correctly, this modification
will not affect or compromise the safety or
integrity of the part.
a. Measure 1.20” (30.5mm) from the center of
the bolt sleeve and make a mark in the
center of the valley between embossments
as shown below.
b. Drill a ~5/16” (~8mm) hole at this location.
4. Starting at the slave cylinder, remove the OEM
parts named in the following diagram beginning
with the input line fitting. Your slave cylinder
will have a separate bleeder bolt that will be
reused.
5. On a workbench (away from the engine), bleed
the Rekluse slave cylinder by this procedure:
c. Use a 4mm Allen key to make the top O-
Ring [#53.1] visible on the adjuster screw
[#28.2].
d. Compress the piston [#28.3] until it bottoms.

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e. Pour clutch fluid into the slave cylinder port.
WARNING
Be sure to use the correct clutch fluid! Check the
cap of the clutch master cylinder to determine
which clutch fluid to use. Failure to use the correct
fluid will result in seal damage and/or failure.
f. Turn the adjuster screw clockwise until it
bottoms, keeping the fluid topped off.
g. Turn the adjuster screw back to the initial
position with the top O-ring visible.
h. Compress the piston until it bottoms out.
Repeat the process until there is no longer
air escaping from the top port when the
piston is compressed.
NOTE: When compressing the piston, fluid
can shoot out from the slave cylinder port. Be
sure to wear eye protection.
6. Check that the ball bearing [#56] is still in place.
7. Install the Rekluse slave cylinder on the bike
using OEM bleeder bolt and input line fitting,
and the provided case O-ring [#53.3].
NOTE: Some models employ a paper gasket as
well as the O-ring to seal the slave cylinder to
the engine. Reuse it if OEM-equipped.

Rekluse Adventure-Bike EXP Page 10
8. Reinstall the modified chain guard.
9. Remove the cap and bladder from the clutch
master cylinder and top off the clutch fluid.
10. Attach the supplied bleed tube to the bleeder
bolt port and loop it into a suitable catch bottle.
11. Pump the clutch lever 3-5 times then hold it
against the bar/grip.
12. Using an 8mm wrench, open the bleed port. Air
and fluid should come out of the bleed tube.
Tighten the bleed port.
13. Slowly release the clutch lever and check the
fluid level in the clutch master cylinder.
14. Repeat the previous 3 bleeding steps until air
no longer comes out of the bleed port. Then,
check that the clutch lever functions properly.
Repeat the bleeding procedure if necessary.
15. Finally, tighten the bleed port and remove the
bleed tube.