Rekluse Core EXP 2.0 User manual

OWNER’S MANUAL
Doc ID: 791-001
Doc Rev: 11/14/2011
©2011 REKLUSE All Rights Reserve
110 E. 43r Street
Boise, I aho 83714
208-426-0659
www.rekluse.com
[email protected]

Page 2
TABLE OF CONTENTS
SAFETY WARNINGS .............................................................................................................................. 3
READ ME FIRST ....................................................................................................................................... 4
Converting Core Manual to Core E P 2.0 .................................................................................. 5
Overview ...................................................................................................................................................... 5
Clutch Parts Diagram ................................................................................................................................... 5
Installation Procedure ................................................................................................................................... 5
Converting E P to Core E P 2.0 .................................................................................................... 6
Overview ...................................................................................................................................................... 6
Installation Procedure ................................................................................................................................... 6
INSTALLATION GUIDE ......................................................................................................................... 7
Overview ...................................................................................................................................................... 8
Installation Ti s ............................................................................................................................................ 8
Tools Needed................................................................................................................................................ 8
Clutch Assembly Diagram ........................................................................................................................... 9
Installation Procedure ................................................................................................................................... 9
Set Clutch Lever Free Play and Check for Lever Free Play Gain.............................................................. 13
Clutch Break-In .......................................................................................................................................... 13
Resetting Installed Ga After Break-In ...................................................................................................... 13
EXP Tuning ................................................................................................................................................ 14
Product Engagement Settings .................................................................................................................... 15
Clutch Cover Installation Guide ................................................................................................... 16
USER’S GUIDE ........................................................................................................................................ 17
Overview .................................................................................................................................................... 18
Setting the Installed Ga ............................................................................................................................ 18
Setting the Installed Ga with a Hot Engine .............................................................................................. 19
Checking the Installed Ga ........................................................................................................................ 20
Understanding the Installed Ga ................................................................................................................ 21
Clutch Lever Free Play vs. Free Play Gain ................................................................................................ 22
Installed Ga O tions ................................................................................................................................. 23
Friction Plates and Wear ............................................................................................................................ 24
S are Friction Disk Set .............................................................................................................................. 25
Clutch Squeal ............................................................................................................................................. 25

Page 3
SAFETY WARNINGS
Doc ID: 192-290
Doc Revision: 081211
Since any Rekluse auto clutch will make your bike appear to be in neutral when in fact it is in gear, it can move
su enly an unexpecte ly if the operator applies the throttle with the bike in gear. Do not apply excessive throttle to
the bike until you are certain the transmission is in neutral. When putting the bike in gear, make sure the engine has
reache i le spee an the brake is applie .
If your throttle sticks open, use the kill switch to stop the engine.
Downhill ri ing with higher auto clutch engagement spee s requires a justments to your ri ing style. For example,
coming over the top of a hill in first gear an slowing to the point that the Rekluse auto clutch isengages the clutch,
your motorcycle will now be “free-wheeling” own the hill. With higher auto clutch engagement spee s, engine
spee engages the Rekluse auto clutch, not wheel spee . It may be possible to reach very high spee s coming
own a hill in a very low gear. When throttle is applie , the Rekluse auto clutch will engage su enly. In this
situation, severe compression braking coul cause an acci ent or engine amage.
WARNING
Clutches are subject to fail uring normal use. Clutch failure coul cause the rear wheel of the motorcycle to lock up
while the vehicle is in motion. Shoul this happen, it may cause the operator to lose control of the motorcycle
causing property amage, personal injury, or loss of life. Always take appropriate safety precautions when ri ing
your motorcycle, inclu ing, but not limite to, proper training to han le emergencies, proper safety gear, an proper
motorcycle maintenance.
WARNING
Improper installation, service or maintenance of this pro uct can cause injury or property amage. Rea these
irections thoroughly before installation. Only a traine an qualifie mechanic shoul install this pro uct. For
assistance or a itional information, please call Rekluse Motor Sports.

Page 4
READ ME FIRST
Doc ID: 193-700
Doc Rev: 030311
There are several crucial steps that must be un erstoo an performe to ensure your Core EXP clutch
will function properly. Failure to properly install, break-in an maintain your clutch components will result in
premature wear or failure.
New Friction Disks Break-In Procedure
• DO NOT put in a new set of friction isks an go racing or for a long ri e without breaking them in
o Soak new friction isks in oil
o Install new friction isks, set installe gap to 1 full turn
o Perform short break-in ri e on new friction isks
o Reset installe gap to 1 full turn + 2 tick marks
o Verify free play gain
• Break-in proce ure is also require when installing new Core EXP clutch components
• If you race, break-in an extra friction isk set an keep it as a spare so you can swap in a fresh set
of friction isks without performing break-in
• Rea the maintenance gui e for more information
Check for free play ain at the start of each ride
• Un erstan how to properly check for free play gain
o Do not ri e if you cannot verify free play gain
o Clutch may seem to work fine but coul be slipping excessively
• If you cannot etect free play gain, reset the installe gap
Tips for settin the installed ap
• For cable actuate bikes, be sure the clutch lever has some free play when fin ing the “starting
point”
• Don’t forget to loosen the set screws before a justing the installe gap with the pressure plate
a juster
o re-tighten the set screws after a justment
• A just the installe gap with the engine col or after it has coole for a 15 minutes with the cover
off
o If you must a just the installe gap with the engine hot, set the installe gap to 1 full turn +
0 tick mark an reset the installe gap after the ri e with the engine col
Visit the Rekluse Core EXP Tech Web Site for More Information
Vi eos, tutorials an tips to help you get the most out of your Core EXP clutch: www.rekluse.com/core-
exp-tech.

Page 5
Converting Core Manual to Core E P 2.0
Doc ID: 195-7500B
Doc Revision: 081211
Overview
Converting your clutch from Core to Core EXP follows the steps outline in the Installation Gui e in the Core EXP
Owner’s Manual with the exceptions note on this page. In summary you will be performing the following steps:
• Removal of the Core (manual mo e) pressure plate
• Reconfiguring the clutch pack with the EXP friction isk
• Installation of the Rekluse EXP pressure plate, lining plate an springs
• Setting the installe gap for break-in
• Checking free play gain
• Performing clutch break-in
• Re-setting the installe gap after break-in
• Verifying proper free play gain
Clutch Parts Dia ram
Installation Procedure
Refer to the 191-7700B installation manual containe in the 791-001 Core EXP Owner’s Manual.
Complete all the steps in the 191-7700B installation manual with the following exceptions:
• In Step 7 you will be removing the Rekluse Core Pressure Plate an springs.
• Skip Steps 9 thru 11 as your Rekluse Core center clutch is alrea y installe .
• Complete all remaining steps in the 191-7700B installation manual.
Note: Be certain you un erstan the clutch pack configuration for your mo el. You will either have 1 or 2 friction
isks remove to accommo ate the EXP clutch pack configuration.

Page 6
Converting E P to Core E P 2.0
Doc ID: 195-7600B
Doc Revision: 111111
Overview
Converting your clutch from EXP to Core EXP follows the steps outline in the Installation Gui e in the Core EXP
Owner’s Manual with the exceptions note on this page. In summary you will be performing the following steps:
• Removal of the EXP friction isk
• Hydraulic Clutch equi ed models only: Removal of the Rekluse a justable throw-out
• Removal of OEM clutch components as irecte in this owner’s manual.
• Installation of the Rekluse Core EXP components an re-use OEM components as irecte in this owner’s
manual.
• Setting the installe gap for break-in
• Checking free play gain
• Performing clutch break-in
• Re-setting the installe gap after break-in
• Verifying proper free play gain
Installation Procedure
Refer to the 191-7700B installation manual containe in this 791-001 Core EXP Owner’s Manual.
Complete all the steps in the 191-7700B installation manual with the following exceptions:
• You will be re-using your EXP friction isk
• If you have a hy raulic clutch equippe mo el you will be installing your OEM throw-out. The Rekluse
a justable throw-out use with the EXP system is not use with the Core EXP system
Note: Be certain you un erstan the clutch pack configuration for your mo el. You will be installing 7 OEM frictions.

INSTALLATION
GUIDE
Doc ID: 191-7700C
Doc Rev: 081211
©2011 REKLUSE All Rights Reserve
110 E. 43r Street
Boise, I aho 83714
208-426-0659
www.rekluse.com
[email protected]

Page 8
Overview
To complete the installation, you will be performing the following steps:
• Removal of your stock pressure plate, clutch pack an center clutch
• Installation of the Rekluse Core center clutch
• Installation of Rekluse rive plates with 7 friction plates from the stock clutch pack (you will
leave out 1 or 2 stock frictions, epen ing on mo el)
• Installation of the Rekluse EXP friction isk
• Installation of the Rekluse EXP pressure plate an springs
• Setting the installe gap for break-in
• Performing clutch break-in
• Re-setting the installe gap after break-in
• Verifying proper free play gain
Installation Tips
• Be sure to use proper eye protection
• Laying the bike on it’s si e makes it easier to work on the clutch an eliminates the nee to
rain the oil
o Be sure to turn off the gas, work in a ventilate area an be prepare to catch any
gas that may rain from vent tubes
• An air or electric impact wrench works well to remove the center clutch nut
o or place the bike in top gear an hol the rear brake while loosening the center
clutch nut
• Channel-lock style pliers work best to ben the tabs of the lock washer up over the center
clutch nut
• Rea an un erstan the maintenance gui e
• Rea tuning options before installation to etermine esire setting
Tools Needed
• 27mm, 29mm, or 30mm socket (for stock center clutch nut)
• 32mm (or 1-1/4”) socket (for Rekluse center clutch nut)
• 5mm hex key (for Rekluse springs)
• 4mm (or 5/32”) hex key (for set screws)
• Channel locks (to ben tabs of Rekluse tab lock washer)
• 8mm, 10mm socket (for removing clutch cover an stock springs)

Page 9
Clutch Assembly Dia ram
Installation Procedure
1. The EXP friction isk, steel rive plates,
pressure plate an pressure plate a juster
come assemble together. When separating
the parts be sure to leave the bottom steel
rive plate on the center clutch.
For 450 class bikes, inclu ing 250+ 2-strokes
the bottom plate package on the center
clutch is the 0.040” (1-mm) thick one as
shown in step 11.
2. Soak the friction pa s of the EXP assembly
an the lining plate in oil for at least 5
minutes.
3. Cable actuated bikes only: A just 5-8 turns of
slack into the clutch cable at the clutch lever
perch.
NOTE: Some bikes may also nee the inline
cable housing a justers a juste in as well.
4. Place the bike in 4
th
or 5
th
gear. If your bike is
carburete turn the fuel off.
5. Lay the motorcycle on its left si e, if your bike
is carburete catch any gas that rains into a
suitable container.
6. Remove the clutch cover.
7. Remove the stock pressure plate bolts an
springs, pressure plate, throw-out, center
clutch an clutch pack.
NOTE: the stock center clutch thrust washer an
throw-out, with nee le bearing an flat washer,
will be re-installe .
8. OPTIONAL STEP: Installing anti-squeal x-
rings
For more information, see the User’s Gui e
section about clutch squeal. If you are still
unsure about installing the x-rings after
rea ing the User’s Gui e, Rekluse
recommen s that you skip this step as they
can be easily a e later.
Install the 6 x-rings in the center clutch
grooves (see picture below).

Page 10
9. Install the Rekluse center clutch, with stock
center clutch thrust washer behin it, onto
the main shaft.
10. Install the Rekluse tab lock washer so the 2
pre-bent tabs in ex own into the 2
correspon ing holes of the Rekluse center
clutch.
11. Install the inclu e Rekluse 32-mm center
clutch nut. Torque the nut to the value
specifie in your motorcycle owner’s
manual—for most mo els 55-60 ft-lbs (80 N-
m) is sufficient. Once tight, ben the tabs of
the Rekluse tab lock washer up to secure the
nut.
NOTE: With all mo els there shoul only be
the Rekluse tab lock washer un erneath the
Rekluse 32-mm nut. Do not re-use any OEM
washers un erneath the Rekluse Nut.
12. Configure clutch pack as shown below an
install onto Rekluse center clutch. You will
install 7 stock frictions an 8 Rekluse drive
plates startin and endin with a Rekluse
drive plate.
NOTE:
Beta Owners Only:
Your clutch pack configuration uses one less
stock friction isk than other mo els. Install 6
stock frictions an 7 Rekluse drive plates
startin and endin with a Rekluse drive
plate.
NOTE: 450 class bikes an 250+ 2-strokes:
Install the .040” (1-mm) Rekluse rive plate
first.
NOTE: Some mo els have a clutch boss
spring in the OEM friction pack. This consists
of two metal rings an one narrow friction
isk. Do Not Re-install these with the Core
EXP
13. Install the EXP friction disk (see below)
against the top Rekluse rive plate.
NOTE: Some OEM Baskets have “half slots”
at the top of the basket tangs—with Rekluse
pro ucts we require that all friction disks,
including EXP disk, are seated into MAIN
basket slots.