Rekluse Motor Sports EXP User manual

©2014 RekluseMotorSports
RekluseMotorSports, Inc.
12000W.FranklinRd.
Boise,Idaho83709
208-426-0659
[e-mail]
REKLUSE MOTOR SPORTS
TheRekluseEXPClutch
INSTALLATION
GUIDE
191-6030
Manual Revision: 041315
OVERVIEW
This kit will replace some of the OEM frictions and drive plates with the EXP disk. The OEM
pressure plate springs will also be replaced with high quality Rekluse springs.
The OEM slave cylinder will be replaced with a Rekluse Adjustable Slave Cylinder.

INSIDE THIS DOCUMENT
oINSTALLATION
oSETTING THE INSTALLED GAP
oCHECKING FREE PLAY GAIN
oBREAK-IN
oMAINTENANCE
oEXP TUNING OPTIONS & ENGAGEMENT SETTINGS
oSETUP SHEET (model specific)
oTROUBLESHOOTING GUIDE
INSTALLATION TIPS
Be sure to use proper eye protection
Laying the bike on its left side makes it easier to work on the clutch and eliminates the need to
drain the oil
oBe sure to turn off the fuel, work in a ventilated area and be prepared to catch any fuel that
may drain from vent tubes
Check the clutch master cylinder cap for the proper clutch fluid to be used
TOOLS NEEDED
8mm socket
Torque wrench (inch-pounds or Newton-
meters)
12mm wrench
8mm wrench
Philips screwdriver
Clutch Fluid
4mm Hex Key

Rekluse EXP Clutch Page 3
BIKE PREP &
DISASSEMBLY
1. Soak the EXP disk in engine oil for 5 min.
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 clutch parts named in the
following diagram.
NOTE:Some of the OEM friction disks and OEM
steel drive plates will be reused. See setup
sheet for specific configuration.

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INCLUDED PARTS
Item
Item Type
Qty
13
EXP Base *
2
50.1
Throw Out Spacer (FOR CERTAIN MODELS)
1
51
Fastener - 1/4-Turn Pin *
6
54
Free Play Gain Rubber Band
1
55
Clutch Cover Gasket (FOR 08-11 KTM 450/505 SXF/XC-F ONLY)
1
60
Pressure Plate Spring (See setup sheet)
-
60.X
EXP Adjustment Spring * (extra adjustment springs are included, see setup sheet)
6
68
Steel Drive Plate (FOR KTM 125/144/150 ONLY)
2
85
Wedge Assembly *
6
86
Adjustable Slave Cylinder Assembly (bleed tube included)
1
* Denotes parts assembled as part of EXP disk assembly
Visit Rekluse.com/support for a full parts fiche illustration and part numbers.

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4. Install the clutch pack with the EXP. See
setup sheet for specific configuration.
*Clutch pack representative only. See setup
sheet for specific configuration.
5. For models listed in the table below
ONLY, install the Rekluse supplied Throw
Out Spacer [#50.1] onto the OEM throw out
assembly.
Bike Model and Year
Throw Out Spacer
99-12 KTM 250/300 2-
Stroke
414-141 (1.5mm thick)*
414-151 (2.4mm thick)*
07-11 KTM 450/505
SXF/XC-F
414-130 (0.75mm thick)
98-05 KTM 125-150
414-130 (0.75mm thick)
06+ KTM 125-150
414-141 (1.5mm thick)
*KTM 250/300 2-Stroke: See Setup Sheet for
Throw Out Spacer note.
6. Install the OEM pressure plate, Rekluse
pressure plate springs* [#60], and OEM
pressure plate bolts and washers.
*See setup sheet for Rekluse pressure plate
spring configuration.
7. Install the clutch cover and torque the cover
bolts OEM specification.
For KTM 450/505 SXF/XC-F, 400/450/530
XCR-W/EXCR-W/XCF-W models ONLY,
install the Rekluse supplied thick Clutch Cover
Gasket [#55].

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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, make sure
that the ball does not come loose.
8. Stand the bike up and lean it on its
kickstand or place it on a suitable bike
stand.
9. Starting at the slave cylinder, remove the
OEM parts named in the following diagram
beginning with the banjo bolt.
10. Bleed the Rekluse slave cylinder by following
the procedure below:
NOTE: Bleed the slave cylinder with it
disconnected from the engine.
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
out.

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c. Pour clutch fluid into the slave cylinder
port. See note below.
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.
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.
11. Check that the ball bearing[#56] is still in
place.

Rekluse EXP Clutch Page 8
12. Install the Rekluse slave cylinder on the bike
using the following parts ending with the
banjo bolt. For 99-05 KTM 250/300 2-
stroke owners: install the included clutch
line and banjo bleeder bolt.
NOTE: Some models have a paper gasket
and/or O-ring seal. Reuse them if OEM
equipped.
13.Husaberg 390/450/570 FE/FX 09-12
Models: See setup sheet for
additional slave cylinder information.
14. Remove the cap and bladder from the clutch
master cylinder and top off the clutch fluid.
NOTE: If the clutch fluid was drained out of
the clutch line the following bleeding
procedure will not work. The system will need
to be bled by pushing fluid from the slave
cylinder up using a syringe. You can
purchase one through Rekluse, part number
790-001.
15. Attach the supplied bleed tube to port on top of
the banjo bolt and loop it into a suitable catch
bottle.
16. Pump the clutch lever 3-5 times then hold it
against the bar/grip.

Rekluse EXP Clutch Page 9
17. Using an 8mm wrench, open the bleed port.
Air and fluid should come out of the bleed
tube. Tighten the bleed port.
18. Slowly release the clutch lever and check
the fluid level in the clutch master cylinder.
19. Repeat the previous 3 bleeding steps until
air no longer comes out of the bleed port.
20. Check that the clutch lever functions
properly and repeat bleeding procedure if
necessary.
21. Remove the bleed tube.
SETTING THE INSTALLED
GAP
NOTE: The “Installed Gap” is the space
between the pressure plate and the EXP
disk created by the adjustment at the slave
cylinder. This gap is what allows the clutch
to spin freely until the desired RPM is
reached for it to engage. This gap can be
finely tuned for optimal performance (see
“Free Play Gain Troubleshooting”) and, with
this product, is externally tunable.
22. Using the long end of a 4mm Allen key, turn
the adjuster screw clockwise until it stops
under moderate pressure. You are trying to
feel for the point at which the throwout will
start to lift the pressure plate. This is called
your starting point.
NOTE: It may take a few tries to find the
point at which the system is bottomed out.
You should feel a distinguishable change in
turning effort at this point.

Rekluse EXP Clutch Page 10
23. Once you have found the starting point,
turn the adjuster clockwise 1 full turn plus
5 marks (or 1+5). This is a good
REFERENCE POINT. Always make final
adjustments according to your free play
gain.
24. Top off the master cylinder with clutch
fluid and reinstall the OEM cap and
bladder.
CHECKING
“FREE PLAY GAIN”
WARNING
Always make sure 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.
NOTE: Before performing this step, please visit
our website at rekluse.com/support to view the
TECH VIDEO entitled “How to Check Free Play
Gain”.
Lever Free Play is essentially the “slack” in the
clutch lever before it starts actuating the clutch.
Applying a light finger pressure will take up this
slack.
“Free Play Gain” is the increase of lever free play
as the auto-clutch engages. This happens when
the RPM increase from idle through around 5000
RPM. Free Play Gain is caused by the expansion
of the EXP disk which lifts the pressure plate away
from the throwout assembly.
Optimal Free Play Gain yields 1/8” (3mm) of
clutch lever movement, measured at the end of

Rekluse EXP Clutch Page 11
the lever. This measurement at the lever
correlates to achieving the ideal installed gap.
The following steps explain two ways to check
Free Play Gain. One will use the rubber band
that has been included in the clutch kit and one
explains using your hand, which you will
perform before every ride.
Place the bike in neutral, start the engine and let
it warm up for 2-3 minutes.
Rubber Band Method:
It is recommended that you use this method
first to find your Free Play Gain so you can
see what it is. Then, check it by hand as well
so that you can effectively and comfortably
check free play gain every time you ride.
Wrap the included rubber band around the
outer end of the handlebar grip and attach it
to the ball end of the clutch lever. See the
following three photos.
With the bike at idle in neutral, rev the engine
to at least 5000 RPM. The clutch lever
should move in about 1/8” (3mm) toward
the handlebar as you rev the engine.
Note: If you are not getting the correct lever
movement, see the “Free Play Gain
Troubleshooting Guide” on the next page.

Rekluse EXP Clutch Page 12
Hand Method:
Free play gain should also be checked using
your hand, as you will check it by hand before
every ride. With the bike at idle, apply enough
pressure to the lever to take up the initial
freeplay (slack) shown in the photos on the
previous page. While continuing to apply
light pressure, rev the engine to at least 5000
RPM. The clutch lever should move in 1/8”
(3mm) under your finger pressure as you
rev the engine.
Free Play Gain
Troubleshooting
Each adjustment should be done in small
increments - one tick mark at a time.
After each adjustment, repeat the rev-cycle until
optimal free play gain is achieved.
Symptom:
- Clutch lever moves in too far (too much
free play gain)
- Clutch has excessive drag
- It is difficult to fully override the clutch
with the lever
Answer: Installed Gap is too small
Solution: Turn the Adjuster Screw inwardly
(clockwise) to increase the Installed Gap.
Symptom:
- Clutch lever does not move enough or
does not move at all (too little free play
gain)
- Clutch is slipping
Answer: Installed Gap is too large
Solution: Turn the Adjuster Screw outwardly
(counter-clockwise) to reduce the Installed Gap. It
may be helpful to re-find the starting point.
BREAK –IN
1. Rev cycles: Warm up the bike for 2-3
minutes. With the bike in neutral and
your hand off of the clutch lever, rev the
engine 20 times to at least 5000 RPM,
letting the engine return to idle between
each cycle. This allows the EXP to break
in.
2. With the engine running, pull in the clutch
lever and click the bike into gear. Slowly
release the clutch lever. The bike should
stay in place, perhaps with some forward
creep. If the bike creeps too much, to the
point of taking off or stalling, the idle may
be too high or the installed gap may be
too small (too much free play gain).
3. Once you have the bike idling with first gear
engaged, slowly apply throttle to begin moving.
To break in the clutch components it is best to
perform some roll-on starts, without using the
clutch lever, in 1st and 2nd gear. In 1st gear,
accelerate moderately to approximately 5000
RPMs and come to a stop—repeat this 20
times. Next, starting in 2nd gear, accelerate
moderately to approximately 5000 RPMs then
come to a stop—repeat this step 10 times.
4. Re-check free play gain at your clutch lever
and adjust if necessary at this point. Your
clutch pack will expand as it gets hot during
normal riding, so it is a good idea to check
your freeplay gain after your bike is warmed up
before each ride.

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WARNING: DO NOT RIDE WITHOUT
SUFFICIENT FREE PLAY GAIN!
Checking free play gain is easy and takes
less than a minute to perform. For optimum
performance and longevity, check freeplay
gain at the start of every ride or if ever you
feel the clutch slipping.
MAINTENANCE
- Keep the adjustable slave cylinder
clean and free of dirt and oil.
- Maintain and replace your chain at
regular intervals as recommended by
the manufacturer. A broken or sloppy
chain could damage the adjustable
slave cylinder and its ability to function
properly.
- Maintain adequate free play gain,
checking before every ride and
adjusting if necessary.
- Inspect your clutch parts every 40
hours for signs of wear or excessive
heat, and replace components as
necessary.
- During EXP disassembly, oil tension may
cause wedge pads to stick to the bases
and dislodge from the wedge. If the base
ramps appear to be in good shape, these
pads can be carefully re-inserted into the
wedge pockets wtihout affecting EXP
performance.
CLUTCH SQUEAL AND
CHATTER
Although it is harmless, some bike models may
have “squeal” or “chatter” coming from the clutch
at low RPM as it engages. Clutch squeal is
caused by the clutch components vibrating as the
clutch engages and can become more audible as
the clutch gets hot. For bike models that tend to
have clutch squeal or chatter here are some
recommendations to reduce or eliminate it:
- Oil: Rekluse recommends that you have
fresh, clean JASO-MA rated oil for best
clutch performance. Dirty or old oil can
make the clutch more likely to squeal or
chatter.
- Clutch Basket: Available for some
models, a Rekluse clutch basket will
eliminate clutch squeal and chatter in most
cases because it is precision machined
from high quality material and includes
long-life clutch dampers. A clutch basket
that is damaged or has worn-out dampers
tends to increase squeal or chatter.
- Core EXP: Upgrading to Core EXP gives
you the option to run anti-squeal x-rings
that will reduce or eliminate clutch chatter
and squeal. Core EXP also has other
benefits including increased oil flow and
torque capacity, longer life billet parts and
stock-like lever feel.
Changing the Installed Gap will NOT affect
clutch squeal or chatter.
PAD
WEDGE