Rekluse Motor Sports EXP Operation manual

©2016Rekluse Motor Sports
Rekluse Motor Sports, Inc.
208-426-0659
[e-mail]
REKLUSE MOTOR SPORTS
The Rekluse Core EXP Kit with Adjustable Slave Cylinder
INSTALLATION &
USER’S GUIDE
Doc ID: 191-7709A
Doc Rev: 091217
OVERVIEW
•This kit replaces the OEM core clutch components including the center clutch hub and pressure
plate with high-quality billet components designed for optimal operation specific to your bike.
•Most of the OEM friction disks will be reused, but all OEM steel drive plates will be replaced with
Rekluse drive plates.

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INSIDE THIS DOCUMENT
oINSTALLATION
oSETTING THE INSTALLED GAP
oCHECKING FREE PLAY GAIN
oBREAK-IN
oMAINTENANCE
oEXP TUNING OPTIONS & ENGAGEMENT SETTINGS
oSLAVE CYLINDER APPENDIX (only some models)
oTROUBLESHOOTING GUIDE
INSTALLATION TIPS
•Watch the “CORE EXP Auto-Clutch Installation Video”by following this QR
code or visiting rekluse.com/videos.
•Read this entire document before performing any steps, so you will know what to expect.
•Be sure to use proper eye protection.
•Laying the bike on its left side makes clutch work easier and eliminates the need to drain the 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 pliers work best to bend the tabs of the washer up over the center clutch nut.
•Use clean, quality JASO MA certified transmission oil for best performance.
•Bikes with taller gearing or modified engines with increased horsepower may require heavier
wedges and/or stiffer pressure plate springs which can be purchased separately from Rekluse.
TOOLS NEEDED
•8mm socket
•27mm socket (most models)
•8mm & 12mm end wrenches
•4mm & 5mm Allen keys
•Torque wrench (in-lb & ft-lb, or N-m)
•Channel-lock pliers
•Hydraulic clutch fluid

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INCLUDED PARTS
Item Item Type Qty
5
Pressure Plate
1
8
Pressure Plate Plug
1
13
EXP Base *
2
16
Steel Lining Plate
1
23
Clutch Cover
1
27
Center Clutch Hub
1
30
Lock-Tab Washer
1
31
Screw Sleeve
6
47
Fastener – M6 Screw (requires 5mm Allen tool)
6
51
Fastener - 1/4-Turn Pin *
6
60
EXP Adjustment Spring * (extra included, see last page for tuning options)
6
60.1,2
Pressure Plate Spring (some models come with 2 different colors of springs)
6
67
Steel Drive Plate – Thick (.060” [1.5mm])
6
67.1
Steel Drive Plate – Thin (.040” [1.0mm])
1
85
Wedge Assembly *
6
86
Adjustable Slave Cylinder Assembly (bleeder bolt included)
1
87
Throwout Assembly (only certain models)
1
88
Core Clutch Spring Kit Assembly
1
* Denotes parts assembled as a component of the EXP disk assembly
Picture above is representative. See the parts list included with the product or visit
Rekluse.com/support for a full parts fiche illustration and part numbers.

Rekluse Core EXP - Hydraulic Page 4
PREP & DISASSEMBLY
1. Lay the bike on its left side. Catch any fuel that
might drain in a suitable container. Remove the
clutch cover.
2. Remove the OEM clutch parts named in the
following diagram. Leave the basket installed.
3. Separate the OEM clutch pack.
Inspect the friction disks for signs of heat or
wear. Replace if they are burnt or worn.For
most models, new friction disks can be
purchased from Rekluse.
4. Inspect the basket for cushion slop or notching.
If notched or worn, it is recommended to install
a Rekluse Billet Clutch Basket (available for
most models).
5. Soak the EXP disk in engine oil for 5 min.

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HUB & CLUTCH PACK
INSTALLATION
6. Install the new center clutch hub on top of the
OEM thrust washer.
NOTE: Rekluse has determined that some models
have slight variance between the center hub and
the main shaft. If your Rekluse center hub seems to
be too tight to fit on the main shaft please follow
these steps:
1. Pre-heat your oven to 200°F (94°C).
2. Using appropriate hot part handling protective
gear, place your center hub in the oven for 10
minutes.
3. Using appropriate hot part handling protective
gear, remove the center hub from the oven and
immediately install on to main shaft.
4. Wait until the center hub has completely cooled.
5. Resume installation at step 6.
This installation process will ensure appropriate
center hub fitment.
7. Torque the nut to 50 ft-lb (70 N-m). Bend both
tabs of the lock washer up.DO NOT OVER
TORQUE, or the clutch will drag and damage
may occur.
8. Install the new clutch pack.
NOTE: The first plate installed is the 0.040”
Rekluse Steel Plate. Proceed to install the rest
of the clutch pack alternating frictions (6x) and
remaining drive plates (6x).
NOTE: Some OEM Baskets have “half-slots” at
the top of the basket tangs. Rekluse products
require that all friction disks, including EXP
disk, are seated into the MAIN (deeper)
basket slots.

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9. Install the included Rekluse throw-out
assembly in the order shown in the following
diagram on top of the stock throw-out rod.
NOTE: If you are missing the top washer, it is
probably stuck to the backside of your OEM
pressure plate.
PRESSURE PLATE
INSTALLATION
10. Place the Lining Plate [#16] onto the Rekluse
Pressure Plate [#5].Adding an oil film between
them will help them stick together for ease of
installation.
11. Install this pressure plate subassembly.
12. Install the pressure plate springs.
Model-Specific Spring Notes:
Beta 250/300cc 2-strokes only:
Your product includes a bi-colored 6-spring kit,
containing 3 of each color: Alternate spring
colors clockwise when installing them to ensure
even clamping force on the pressure plate.
CLUTCH COVER
13. Your new Core EXP clutch is taller than the
OEM clutch, so the Rekluse Clutch Cover has
been designed for clearance with all moving
parts. You must use the Rekluse Clutch Cover
or interference and clutch damage will occur.

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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.
14. Stand the bike up and lean it on its kickstand or
place it on a suitable bike stand.
15. On a workbench (away from the engine), bleed
the Rekluse slave cylinder by this procedure:
a. Use a 4mm Allen key to make the top O-
Ring [#53.1] visible on the adjuster screw
[#28.2].
b. Compress the piston [#28.3] until it bottoms.
c. 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.
d. Turn the adjuster screw clockwise until it
bottoms, keeping the fluid topped off.
e. Turn the adjuster screw back to the initial
position with the top O-ring visible.

Rekluse Core EXP - Hydraulic Page 8
f. 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.
16. Check that the ball bearing [#56] is still in place.
NOTE: The Rekluse slave cylinder comes
preassembled in the kit. If the parts become
separated, assemble them in the following order:
Rekluse slave cylinder, O-ring, then the supplied
paper gasket.
17. At the slave cylinder, remove the OE banjo bolt
and fluid line from the stock slave cylinder. You
can leave the bleeder bolt in the stock slave
cylinder, since a new one is provided with the
Rekluse slave cylinder assembly.
18. Attach the clutch fluid line to the Rekluse slave
cylinder using the OE banjo bolt and the 2 new
crush washers from Rekluse. Make sure the
banjo fitting is between the 2 crush washers.
19. Tighten the banjo bolt with your hand until
snug. (You will torque it to spec once installed
on the bike.)
OE Banjo Bolt
OE Crush
Washers
OE Banjo
Rekluse Crush
Washers
Rekluse
Bleeder

Rekluse Core EXP - Hydraulic Page 9
NOTE: Some models have a piston
diaphragm seal on the stock slave cylinder.
DO NOT REUSE this seal if OE equipped.
20. With the clutch fluid line attached to the
Rekluse slave cylinder, remove the OE slave
cylinder from the engine. Keep the OE bolts for
reuse.
21. Mount the Rekluse slave cylinder to the engine
by lightly threading the two shorter OE bolts on
the left side until finger tight.
22. Remove the OE chain guard screw sleeve
from the plastic chain guard by gently pushing
it out the backside.
23. Insert the new Rekluse chain guard screw
sleeve into the screw slot.
24. Reattach the chain guard to the slave cylinder
using the longer OE screw.

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NOTE: The Rekluse screw sleeve is slightly taller
than the OE screw sleeve. You will need to use the
Rekluse screw sleeve to help ensure a good seal to
the engine case.
25. Tighten all the slave cylinder screws to OE
specifications.
26. Torque the banjo bolt to 18 ft-lb (25 N-m) per
OE specification.
27. Optional: If you purchased the Rekluse Slave
Guard accessory (available for most models),
install it now using the instructions in the kit.
28. Remove the cap and bladder from the clutch
master cylinder and top off the clutch fluid.
29. Attach the supplied bleed tube to the bleeder
bolt port and loop it into a suitable catch bottle.
30. Pump the clutch lever 3-5 times then hold it
against the bar/grip.
31. Using an 8mm wrench, open the bleed port. Air
and fluid should come out of the bleed tube.
Tighten the bleed port.