Rekluse Motor Sports Core Manual User manual

©2012 RekluseMotorSports
RekluseMotorSports, Inc.
12000W FranklinRd
Boise,Idaho83709
208-426-0659
[e-mail]
REKLUSE MOTOR SPORTS
TheRekluseCoreManualClutchKit
INSTALLATION
GUIDE
Doc ID: 191-7003
Doc Rev: 042513
INSTALLATION TIPS
Be sure to use proper eye protection
Laying the bike on its left side allows for easy clutch access and eliminates the need to drain oil
An air or electric impact wrench works well to remove the center clutch nut, or you can place the
bike in top gear and hold the rear brake while loosening the center clutch nut with a socket
Channel-lock style pliers work best to bend the tabs of the washer up over the center clutch nut
TOOLS NEEDED
8mm socket
27mm socket
Torque wrench (in-lb. or N-m)
Channel-lock pliers

Rekluse Brake Kit Page 2
BIKE PREP &
DISASSEMBLY
1. Soak the supplied friction disk in engine oil
for 5 minutes.
2. Lay the bike on its left side. Catch any fuel
that might drain in a suitable container.
Remove the clutch cover.
3. Remove the OEM parts named in the
following diagram.

Rekluse Brake Kit Page 3
Tips:
a. Use a hammer and large screw driver to
bend down the tabs of the tab washer.
b. Be careful that the drive pins do not fall
into the engine while disassembling.
4. Separate the clutch pack.
5. Remove the center hub assembly from the
bike. Make sure the thrust washer is in
place on the mainshaft and not stuck to the
bottom of the center hub assembly.

Rekluse Brake Kit Page 4
6. NOTE: The OEM dampers inside the
center hub assembly shrink due to heat and
use. Loose or sloppy dampers will shorten
the life of your clutch. Inspect the dampers
before proceeding and replace if necessary.
Inspect the dampers using the procedure
described in the “Read Me First” document,
or by the following procedure.
Inspecting the dampers by hand:
With the center hub assembly in your hands,
place your thumbs on the inner hub at the
location of the embossed part numbers and try
to spin the inner hub back and forth inside the
outer hub. Rekluse recommends replacing the
dampers if you feel slop between the two hubs.
7. Remove the 6 rubber dampers from the
center hub assembly.

Rekluse Brake Kit Page 5
INCLUDED PARTS
Item
Item Type
Qty
6
Pressure Plate
1
27
Outer Hub
1
47
Fastener - M5 x 20 T-25 Torx Screw (T-25 Torx bit included)
6
63
Steel Drive Plate (2-stroke models have 9)
10 (9)
69*
Friction Disk (*4-stroke models only)
1
Visit Rekluse.com/support for a full parts fiche illustration and part numbers.

Rekluse Brake Kit Page 6
CLUTCH PACK
INSTALLATION
8. Install the 6 OEM rubber dampers and OEM
inner hub onto the Rekluse Outer Hub [#27].
9. Install the new Center Hub Assembly into
the motorcycle.
10. Reinstall the OEM tab washer and center
clutch nut torqueing the nut to OEM
specification.
11. Seat the 6 OEM drive pins into the Rekluse
outer hub.

Rekluse Brake Kit Page 7
12. Install the first drive plate in the orientation
shown [all drive plates will follow this
orientation].
NOTE: Proper orientation of the drive plates
is critical for optimal clutch performance. If
you install them backwards, the clutch will
still function but will lack proper modulation
performance.
13. Install the rest of the clutch pack, noting the
number and order of plates shown.
4-stroke and 2-stroke models will use
different clutch packs.
4-stroke Models:
2-stroke Models:

Rekluse Brake Kit Page 8
14. Reinstall the OEM throwout.
PRESSURE PLATE
INSTALLATION
15. Install [#6] Pressure Plate.
16. Install the OEM slider ring and Belleville
spring.
17. Install the OEM pressure ring followed by
the Rekluse Pressure Plate Screws [#47].
NOTE: There are 3 possible settings on the
OEM Pressure Ring. Replace to the OEM
setting.
18. Reinstall the clutch cover, torqueing the
cover bolts to OEM specification.
MAINTENANCE
- To prolong the life of the clutch, inspect your
rubber hub dampers every 20 hours for
450 SX-F models (including factory edition),
and every 30 hours for all other bikes.
Replace the dampers if the interaction
between the two hubs is loose or sloppy.
See the “Read Me First” page for inspection
procedure.
- Inspect all of your clutch parts every 40
hours for signs of wear or excessive heat,
and replace components as necessary.