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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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

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4.Place the pressure plate springs into the assembled
clutch, then insert the screw sleeves into the springs. See
the following chart for spring information.
Pressure Plate Spring Information
The upgrade kit includes lighter pressure plate springs. You
have the option of reusing your current pressure plate
springs or using the new springs depending on torque
capacity and clutch lever pull preference. Differences in
clamping force and torque capacity will vary by model.
250F: There are two spring options.
a.Silver springs will give the feel of a smoother clutch with
a clutch lever pull about equal to OE.
b. Gold springs will yield a more aggressive clutch with
clutch pull slightly higher than OE. Rekluse recommends
installing silver springs for a more superior lever feel and
better matched torque capacity to motor output.
450F/250 2-Stroke: There are three spring options.
a.Gold springs will give the feel of a smoother clutch with a
clutch lever pull lighter than OE.
b.Red springs will yield a more aggressive clutch with
clutch pull similar to OE.
Clutch Lever Pull
Torque Capacity
250F
-Gold Springs
-Silver Springs
OE
-Silver Springs
-Gold Springs
OE

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c. Using three of each spring (3 red and 3 gold) will result
in an in-between setup. Be sure to alternate springs
when using 3 red and 3 gold to keep even pressure on
the clutch. Rekluse recommends installing gold springs
for a more superior lever feel and better matched torque
capacity to motor output.
5.Insert the pressure plate bolts into the screw sleeves.
Do not reuse the OE springs, or clutch cover
interference will occur!
OE
Clutch Lever Pull
Torque Capacity
450F/250 2-Stroke
OE
-Gold Springs
-Red Springs
-Red Springs
-Gold Springs

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6.Using a torque wrench, tighten the pressure plate bolts to
9 ft-lb (12-N-m).
It is very important that you understand how to set the
installed gap in your new clutch, and be able to verify the
installed gap by checking Free Play Gain.
The “installed gap” is the free space in the clutch pack when
the EXP disk is disengaged (collapsed). This gap allows the
clutch to spin freely until the engagement RPM is reached
and the EXP disk expands to close the gap and apply
pressure to the pressure plate, which in turn drives the
motorcycle forward.
The installed gap is what allows the auto function of the
product to perform properly. Setup, break-in, and rechecking
the installed gap is CRUCIAL. Failure to properly maintain
your installed gap can result in premature wear or failure of
your clutch.
SET THE INSTALLED GAP AND
CHECK FREE PLAY GAIN

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Failure to check and verify Free Play Gain can cause
failure or damage to this product.Setting the correct
installed gap is critical for clutch performance.
Setting the installed gap and checking Free Play Gain is a 4-
step process. It is important to follow each step to ensure
that your new clutch functions as designed.
Step 1: Set the installed gap
Do not ride your bike without adjusting the installed
gap. You will not be able to disengage the clutch until
you set the installed gap.
1.Using a 5 mm hex key, insert the long end of the key into
one of the two hex holes in the pressure plate adjuster.
2.By hand, gently thread the pressure plate adjuster
clockwise until there is a noticable change in turning effort.
3.Find the adjuster mark on the pressure plate adjuster, then
find where it aligns with the closest tick mark on the
pressure plate. This is your starting point.

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4.Check for clutch lever free play. If the lever is tight
against the perch, then adjust a few turns of slack into
the cable and re-check your starting point. (If there is not
enough adjustment at the perch, you may need to adjust
using the in-line cable adjuster).
Note: The pressure plate adjuster should bottom out and lift
against the center clutch nut, not the throw-out. Slack in the
clutch cable ensures that you find the correct starting point.

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5.Insert the short end of the 5 mm hex key into the pressure
plate adjuster, then turn it clockwise one full turn plus 2
tick marks past the starting point.
Note: As you turn the adjuster, the clutch may slip and start
to spin before you reach 1-full turn. With the bike in gear,
you can hold the rear brake for leverage.
6.Once the installed gap is set, use a 4 mm hex key to
slowly tighten the two locking set screws in the pressure
plate adjuster to lock it into place. Tighten the screws
evenly and in small steps.
7.Torque to 40in-lb (4.5 N-m).

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Note: The tops of the set screws should be flush or slightly
below flush with the top of the adjuster when torqued
correctly.
8.With the gap adjusted, readjust the clutch lever free play to
OE specification.
9. Reinstall the clutch cover gasket or O-ring cord, then
reinstall the clutch cover.
10. Reinstall the OE
oil plug if it was
removed during
disassembly.
11. Torque clutch
cover bolts to OE
specification.
Reinstall clutch cover
gasket or O-ring

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Step 2: Learn how to check Free Play
Gain
If you are familiar with Free Play Gain, check for Free Play
Gain then skip to Step 3 -“Break-in the new clutch.”
If Free Play Gain is new to you, follow the instructions below
to help you learn this important step. You can also view the
video entitled “How to Check Free Play Gain” on our website
at www.rekluse.com/support/videos.
Free Play Gain is different from the “normal” free play you
are used to with your stock clutch. With the Rekluse auto
clutch, Free Play Gain is the result of the EXP disk
expanding and lifting the pressure plate to engage the
clutch.
Free Play Gain happens when the engine’s RPM increases
from idle to above approximately 5,000 RPM and the EXP
closes the installed gap. The amount of Free Play Gain you
feel in the lever corresponds to the amount the pressure
plate has been lifted by the EXP disk expansion.
Checking Free Play Gain allows you to externally monitor
the installed gap so you can know when to make an
adjustment if the installed gap is too large or too small.
The correct installed gap is verified by observing and feeling
the increased free play movement in the clutch lever. This
extra movement is called “Free Play Gain.”

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If there is too much Free Play Gain, the installed gap is too
small. The bike may drag and stall because it has difficulty
disengaging the clutch. It may also be difficult to shift. Too
much Free Play Gain will not hurt the clutch, but it will
negatively affect clutch performance.
With too little or no Free Play Gain, the installed gap is too
large. This means when the EXP is fully expanded it does
not lift the pressure plate. The clutch may slip and make the
bike seem like it is losing power. The bike may not move
forward even though the engine RPM increases as if the
clutch lever is slightly pulled. Too little Free Play Gain will
cause the clutch system to burn up.
Optimal Free Play Gain yields 1/8” (3 mm) of clutch lever
movement, measured at the ball end of the lever. This
measurement at the lever correlates to achieving the ideal
installed gap.
The following steps explain 2 ways to check Free Play Gain.
One way uses the rubber band Rekluse includes in the
clutch kit, and one uses your hand. You can use either
method to check for Free Play Gain.
Rekluse recommends that you begin with the rubber band
method first to check for Free Play Gain and then learn the
hand method. The rubber band will help you learn how to
recognize Free Play Gain until you are comfortable with the
hand method. Learning to check Free Play Gain by hand
effectively and comfortably can make it easy to check Free
Play Gain every time you ride.
Two Ways to Check for Free Play
Gain

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The Rubber Band Method
Use the rubber band method for the initial set up. It can also
be used before each ride until you feel comfortable checking
the Free Play Gain using the hand method.
BEFORE YOU BEGIN, verify that the bike is in NEUTRAL
before checking Free Play Gain. Failure to do so may
result in the bike lurching forward, and loss of control
and/or injury may result.
A Rekluse auto-clutch can make your motorcycle appear
to be in neutral when in gear, even when the engine is
running and clutch lever released.
Motorcycles equipped with a Rekluse auto-clutch can
move suddenly and unexpectedly and cause riders to
lose control. To avoid death, serious injury, and/or
property damage, always sit on the motorcycle to start
it.
a) Before you begin, place the bike in NEUTRAL, start
the engine and let it warm up for 2-3 minutes to idle
down and warm the engine oil.
b) Stretch the included rubber band between your
thumbs, then place the top end of the rubber band on
the outer end of the left handlebar grip.