Rekluse Motor Sports Core EXP 3.0 Operation manual

©2017 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[e-mail]
INSTALLATION & USER’S
GUIDE
Core EXP 3.0 TorqDrive Clutch
Upgrade Kit for Cable-Actuated Motorcycles
Doc ID: 191-7800A
Revision: 041019

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TABLE OF CONTENTS
OVERVIEW ...........................................................................3
INSTALLATION TIPS ............................................................3
TOOLS...................................................................................4
INCLUDED PARTS ...............................................................4
DISASSEMBLE THE CLUTCH .............................................5
CLUTCH PACK INSTALLATION...........................................6
Notes for Clutch Pack Installation: .....................................8
PRESSURE PLATE INSTALLATION..................................10
Pressure Plate Spring Information ...................................11
SET THE INSTALLED GAP AND CHECK FREE PLAY
GAIN ....................................................................................13
Step 1: Set the installed gap ............................................14
Step 2: Learn how to check Free Play Gain ....................18
Two Ways to Check for Free Play Gain ..............................19
The Rubber Band Method................................................20
The Hand Method ............................................................22
Step 3: Break-in the new clutch...........................................24
FREE PLAY GAIN ADJUSTMENTS ...................................27
MAINTENANCE...................................................................28
Disk inspection examples ................................................29
TROUBLESHOOTING.........................................................31
Performance issues .........................................................31
Clutch noise .....................................................................31
EXP TUNING OPTIONS......................................................32
Changing the EXP springs ...............................................33
NEED ADDITIONAL HELP?................................................35

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Doc Rev: 041019
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This guide shows you how to upgrade your OE (Original
Equipment) core clutch parts with your new Rekluse
upgraded clutch parts. The following parts are replaced:
·Steel drive plates
·Lining plate
·EXP disk
·OE Friction Disks
·Read the safety information sheet
included with your kit.
·If you install this product for a customer or
another person, instruct them to read the
Safety Information document and the Installation and
User Guide before operating the bike with the product.
·Protect eyes and skin –wear safety glasses and thin
disposable work gloves.
·Read this entire document before performing any steps.
·Lay the bike on its left side when replacing the clutch.
This makes the clutch work easier and eliminates the
need to drain the oil.
·For optimal clutch performance Rekluse recommends
using fresh, clean oil that meets JASO-MA oil rating
requirements. Rekluse offers Factory Formulated Oil™
developed specifically for Rekluse products. Rekluse
Factory Formulated Oil is a perfect complement to any
OEM or aftermarket wet clutch. Visit www.rekluse.com to
learn more.
·Bikes with taller gearing or modified engines with
increased horsepower may require heavier wedges.
These can be purchased separately from Rekluse.
OVERVIEW
INSTALLATION TIPS

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4 mm
Hex Key
5 mm
Hex Key
Torque Wrench
8 mm
Socket
Hydraulic clutch
fluid
Flat blade
Screwdriver
Fluid Catch
Container
Open-ended
Wrenches
Each upgrade kit includes a set of TorqDrive friction disks,
steel drive plates, basket sleeves, an EXP disk, and
pressure plate springs. Please refer to the Setup Sheet for a
listing of included parts for your model of bike.
Or visit us at www.rekluse.com/support for a full parts fiche
illustration and part numbers.
TOOLS
INCLUDED PARTS

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1.Turn the fuel petcock to “OFF” if applicable.
2.Lay the bike on its left side. Catch any fuel that
might drain in a suitable container.
3.Use an 8 mm socket to remove the clutch cover.
DISASSEMBLE THE CLUTCH

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4.Remove the following parts from the clutch:
·Pressure plate bolts
·
Pressure plate springs
·
Pressure plate
·Lining plate
·
EXP disk
·
Clutch pack
Each clutch pack comes with a set of steel plates, a set of
friction disks, basket sleeves, and an EXP disk. The
specifics of the clutch pack depends on the bike. The height
of the assembled clutch pack and specific information for
each bike can be found on the Setup Sheet.
1.Soak the friction disks and EXP disk in
new oil for at least 5 minutes. Make sure
the EXP and friction disks are coated on
both sides.
CLUTCH PACK INSTALLATION
Clutch pack
Pressure plate
and lining plate
Bolts and
springs
EXP disk

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2.Inspect the clutch basket for notching. Do not install
sleeves or use product with a notched basket. Notched
basket tang faces can cause the sleeves to break. Do not
use baskets that have been filed, machined, or modified
on the tangs. Replace basket if necessary.
Failure to inspect the basket and replace if necessary
could result in death, serious injury, and/or property
damage.
3.Install ALL the Rekluse basket sleeves into the basket
slots. Make sure the sleeve tabs sit against the inside of
the basket, then push the sleeves down until they contact
the bottom of the tang slot. See pictures for reference.
OE
basket
Basket
sleeve

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Note: When seated in the basket, the sleeves may stick
slightly above or below flush with the top of the basket. This
is normal.
Notes for Clutch Pack Installation:
·The clutch pack will be replaced with all new frictions and
steel drive plates. Do not reuse the old clutch pack.
·Some friction disks are marked with a small colored dot.
This mark is used for processing and can be ignored.
·The orientation of the clutch pack is different for each bike.
The number and thickness of drive plates included in the
kit also varies by bike. Please refer to the Setup Sheet for
specific information for your bike before installing the
clutch pack.
Install all the basket sleeves

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·Some OE basket have “half slots” at the top of the basket
tangs. Rekluse products require the entire clutch pack be
installed into the MAIN (deeper) basket slots. Installing the
clutch pack and EXP disk in the “half slots” will cause
performance issues. See the following picture for
reference.
4.
Begin installing the Rekluse clutch pack starting with a
steel drive plate.
5.Continue installing the clutch pack according to
installation order listed on the Setup Sheet.
Install clutch pack
and EXP disk in
the main basket
slots

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1.Add a light film of oil between the lining plate and pressure
plate (this will help the plates stick together for ease of
installation).
2. Place the new steel lining plate onto the Rekluse pressure
plate by lining up the index tabs and slots. Do not reuse
the old lining plate.
3.Install the pressure plate subassembly.
PRESSURE PLATE INSTALLATION