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.

Page 11
14. All models exce t Beta, CRF250X,
Husqvarna 450/510 and Gas Gas
Install the stock throw-out, with nee le
bearing an flat washer on top, onto the
throw-out ro .
NOTE: If you are missing the flat washer, it is
probably stuck to the backsi e of your stock
pressure plate.
15. Beta, CRF250X, Husqvarna 450/510 and
Gas Gas owners only:
Install the inclu e Rekluse throw-out
assembly with the inclu e thrust washers
an nee le bearing as shown below. A
separate note showing the same
configuration is also package with the throw-
out assembly.
16. Place the lining plate onto the Rekluse
pressure plate as shown below. In ex the
teeth of the lining plate into the correspon ing
recesses in the Rekluse pressure plate.
17. Install Rekluse pressure plate with lining plate
onto the Rekluse center clutch. Hold the
pressure plate and linin plate to ether
while installing onto center clutch to ensure
the lining plate teeth remaine in exe into
the pressure plate recesses.
18. Install the inclu e Rekluse springs into the
pockets of the pressure plate. Place the bolts
an sleeves into the springs an threa each
bolt in a couple of turns. Next, rotate each
sprin one turn counter-clockwise to
ensure the sprin is properly located in its
sprin pocket (see picture below).
Torque each bolt to 9 ft-lbs (12 N-m).
BOTTOM OF SPRING
LOCATED IN POCKET

Page 12
NOTE: The pressure plate comes with the set
screws an a juster installe . For reference, if
the set screws are ever remove , the knurle
si e shoul face up.
19. Apply oil to the threa s of the pressure plate
a juster an pressure plate.
20. Insert the long en of a 5 mm hex key into
either of the two 5-mm hex holes in the
pressure plate a juster. By hand, turn the
short en of the hex key clockwise to threa
the pressure plate a juster inwar . Usin
moderate pressure, turn the a juster in until
it comes to a stop against the center clutch
nut. Make note of where the mark on the
a juster lines up with the tick marks on the
pressure plate. This is your startin point.
NOTE: To accurately fin the starting point
you shoul turn the short en of a stan ar
5mm hex. Using the long en , or a tool with
too much leverage won’t allow for proper
feeling of the starting point.
On hy raulic mo els you will feel slight
resistance as you threa the a juster in ue
to the hy raulic pressure. Be sure your
starting point is when the pressure plate
a juster stops on the center clutch nut.
21. Cable actuated models only: Check to make
sure there is lever free play. If the clutch
lever is tight, then a just a few more turns of
slack into the cable an repeat step 16.
22. Insert the short en of the 5-mm hex key into
either of the two 5-mm hex holes in the
pressure plate a juster an turn the pressure
plate a juster in, clockwise, one full turn past
the startin point you foun in step 17. Use
the tick marks to keep track of where you
starte .
NOTE: As the pressure plate gets raise by
the a juster, the clutch may slip an start to
spin before you reach 1-full turn. With the
bike in gear you can hol the rear tire to turn
against.
23. Once the installe gap is set, use a 4-mm hex
key to tighten the two set screws in the
pressure plate a juster to lock it into place.
Tighten the screws evenly in 3-4 steps until
the tops of the set screws are flush with or
slightly below the top of the a juster. Do not
over-tighten the set screws or you may
amage the threa s in the pressure plate
a juster. It is not necessary to put threa
locking compoun onto the set screws.

Page 13
24. Install the inclu e Rekluse clutch cover re-
using your OEM clutch cover gasket or o-ring.
See appen ix A at the en of this manual for
specific instructions for installing the Rekluse
clutch cover.
NOTE: You must use the Rekluse clutch
cover or you will amage the Core EXP
Clutch
Set Clutch Lever Free Play and
Check for Lever Free Play Gain
25. A just the clutch lever free play at the clutch
perch accor ing to your service manual or
personal preference. You must have at least
a slight amount of clutch lever free play just
like the stock clutch.
Place the bike in neutral, start the engine an
let it warm up for 2-3 minutes.
With the bike at i le, pull on the clutch lever
lightly with a single finger so the lever free
play is taken up but the clutch is not
isengage . While continuing to apply light
pressure, rev the engine to at least 5000
RPM. The clutch lever should move in
under your fin er pressure sli htly as you
rev the en ine. This is known as free play
gain.
Measure at the en of the clutch lever, the
lever shoul move inwar a minimum of 1/8”
(3-mm) as the engine is revve .
See the User’s Guide for more information
about Free Play Gain.
If there is no lever free play gain, you will
nee to reset the installe gap as escribe in
steps 16 through 20.
Clutch Break-In
26. With the engine running, pull in the clutch
lever an click the bike into gear. Slowly
release the clutch lever. The bike shoul stay
in place, perhaps with some forwar creep or
tension on the chain.
Once you have the bike i ling with first gear
engage , slowly apply the 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 2
n
an 3
r
gear. In
2n gear, accelerate mo erately to
approximately 5000 RPM an come to a
stop—repeat this 20 times. Next, starting in
3
r
gear, accelerate mo erately to
approximately 5000 RPM then come to a
stop—repeat this step 10 times.
Resettin Installed Gap After Break-
In
27. After break-in, the installe gap must be
reset ue to the initial “seat-in” of the
clutch components. Before resetting the
installe gap, allow the clutch to cool for
20 minutes with the cover off.
Adjust 3-4 turns of slack into the clutch
cable at the clutch perch. Remove the clutch
cover an loosen the two locking set screws
in the pressure plate a juster. Using a 5-mm
hex key, turn the pressure plate a juster
counter-clockwise until it is loose.
Follow steps 20 through 23 again to reset the
installe gap, but reset to 1 full turn plus 2
tick marks for the post break-in installe gap.
This is the recommen e Rekluse installe
gap setting.
Be sure to tighten the two locking set screws
in the pressure plate a juster to lock it in
place. A just the clutch lever free play as
previously instructe .
Check for free play gain as escribe in step
25. With an installe gap of 1 turn + 2 tick
marks, the free play gain shoul be

Page 14
approximately 1/8” (3-mm) measure at the
en of the lever. If you cannot feel any free
play gain in the lever you must reset the
installe gap.
Read the included User Guide for more
information about setup an maintenance of
the Core EXP clutch
NOTE: Whenever installing new friction isks
or a new EXP assembly, you must go through
the break-in proce ure as escribe in this
manual. Always soak new friction isks in oil
prior to installing.
NOTE: Checking free play gain is simple an
takes less than a minute to perform. For
maximum friction isk life, take a moment to
check for free-play gain at the start of every
ri e.
WARNING: DO NOT RIDE WITHOUT
SUFFICIENT FREE PLAY GAIN. Your clutch
may seem to operate ok but it is not getting
full clamping force an may slip without you
recognizing it. This can lea to premature
failure of the clutch isks inclu ing the EXP
friction isk.
EXP Tunin
A justing the engine i le spee to match your engagement setting is important an greatly affects the
overall feel of how the EXP friction isk engages. To prevent freewheeling an maximize engine braking,
set the i le so there is a slight amount of rag while the bike is i ling in gear an warme up. The i le
shoul not be so high as to move the bike forwar in gear with the throttle close . However, with a small
opening of the throttle the bike shoul move forwar .
To change springs, remove 3 of the ¼ turn pins from one si e of the EXP, replace springs, an re-install ¼
turn pins. Next, flip the EXP friction isk over an repeat on the other si e if necessary. To maintain even
pressure, when using two ifferent color spring sets, install one set of 3 on one si e of the EXP an the
remaining set of 3 on the other si e.
The EXP friction isk comes set with the recommen e “Me ium” setting from Rekluse. See following
table for spring setting options by pro uct number.

Page 15
Product En a ement Settin s
Make Bike Model Product Low Sprin s
Medium
Sprin s Hi h Sprin s
Beta 350,400,450,520 RMS-7723B 6 Re 3 Re 3 Blue 6 Blue
Gas Gas 250/300 RMS-7700B 6 Re 3 Re 3 Blue 6 Blue
Hon a CRF250R RMS-7712B 3 Silver 3 Re 6 Re 3 Re 3 Blue
Hon a CRF250X RMS-7712B 6 Silver 3 Silver 3 Re 6 Re
Hon a CRF450R RMS-7713B 6 Re 3 Re 3 Blue 6 Blue
Hon a CRF450R RMS-7714B 6 Re 3 Re 3 Blue 6 Blue
Hon a CRF250R RMS-7716B 3 Silver 3 Re 6 Re 3 Re 3 Blue
Hon a CRF450X RMS-7719B 6 Re 3 Re 3 Blue 6 Blue
Husaberg FE 390/450/570 RMS-7727B 6 Re 3 Re 3 Blue 6 Blue
KTM 450/505 SXF/XCF RMS-7730B 6 Blue 3 Blue 3 Gol 6 Gol
KTM 400/450/530 EXC/XCR RMS-7732B 3 Re 3 Blue 6 Blue 3 Blue 3 Gol
KTM 350 SXF/XCF RMS-7735B 3 Silver 3 Re 6 Re 3 Re 3 Blue
KTM 250/300 SX/XC/XCW RMS-7736B 6 Re 3 Re 3 Blue 6 Blue
KTM 250 SXF/XC-F/XCFW RMS-7738B 3 Silver 3 Re 6 Re 3 Re 3 Blue
Kawasaki KX250F RMS-7740B 3 Silver 3 Re 6 Re 3 Re 3 Blue
Kawasaki KX450F/KLX450F RMS-7745B 6 Re 3 Re 3 Blue 6 Blue
Husqvarna TC/TE 310 RMS-7755B 6 Silver 3 Silver 3 Re 6 Re
Husqvarna TC/TXC/TE 250 RMS-7755B 6 Silver 3 Silver 3 Re 6 Re
Husqvarna TC/TE 450/510 RMS-7756B 6 Re 3 Re 3 Blue 6 Blue
Kawasaki KX250F RMS-7761B 3 Silver 3 Re 6 Re 3 Re 3 Blue
Suzuki RMZ250 RMS-7761B 3 Silver 3 Re 6 Re 3 Re 3 Blue
Suzuki RMZ450 RMS-7764B 3 Re 3 Blue 6 Blue 3 Blue 3 Gol
Suzuki RMZ250 RMS-7767B 6 Re 3 Re 3 Blue 6 Blue
Yamaha YZ250 RMS-7770B 6 Re 3 Re 3 Blue 6 Blue
Yamaha WR250F RMS-7771B 3 Silver 3 Re 6 Re 3 Re 3 Blue
Yamaha YZ250F RMS-7771B 3 Silver 3 Re 6 Re 3 Re 3 Blue
Yamaha YZ450F RMS-7773B 6 Blue 3 Blue 3 Gol 6 Gol
Yamaha WR450F RMS-7773B 6 Blue 3 Blue 3 Gol 6 Gol
Yamaha YZ450F RMS-7776B 6 Blue 3 Blue 3 Gol 6 Gol

Page 16
Clutch Cover Installation Guide
Doc ID: 199-300
Manual Revision: 052711
Copyright 2011 REKLUSE All Rights Reserve
Installation:
The Rekluse clutch cover provi es clearance for all Rekluse clutch systems using either the OEM gasket
or o-ring. If the OEM o-ring or gasket is amage it shoul be replace to guarantee proper sealing.
Some mo els require spacing or a justment of the brake pe al to gain clearance of the cover. See mo el
notes below for specific instructions.
Increased Oil Capacity:
The Rekluse clutch cover is slightly eeper than the stock cover, increasing the oil capacity of some
mo els very slightly. If your motorcycle or ATV uses a ip-stick, sight glass or oil-level check bolt, continue
to use the metho escribe in the vehicle’s owner’s manual to fill to the proper oil level. If your vehicle’s
owner’s manual only specifies an oil amount, a 10cc (10ml) a itional oil to the amount specifie in the
manual.
Model Notes:
• All Honda Models:
A length of o-ring cor is provi e with your cover as the OEM o-ring occasionally oes not fit back
into the Rekluse or OEM cover after removal. Place a ab of grease into the o-ring groove in four
spots to hol the o-ring cor in the groove. Lay o-ring into groove aroun cover. Trim o-ring so that
you have minimal gap between mating en s of o-ring. Ensure that the gap in the o-ring cor is
place at the top-most (12 o’ clock) position on the clutch cover.
• CRF250X:
To utilize the oil fee ing feature in the Rekluse clutch cover you must replace the OEM throw-out
assembly with the inclu e 743-006 Rekluse throw-out assembly. If you o not use the Rekluse
throw-out assembly you will have clutch cover interference
• KTM 400/450/505/530, Husaber 390/450/570 FE, FX:
To provi e a equate clearance between the cover an brake pe al tip, remove the OEM tip an
replace it with the inclu e Rekluse tip using the provi e har ware an threa lock. Your pe al
position will nee to be lowere about ¼-inch (6-mm) to gain necessary cover clearance. The
Rekluse tip is taller to allow for this. Refer to your owner’s manual for instructions about properly
a justing brake pe al height.
• KX250F/KX450F/KLX450F/YZ250 2 stroke:
To provi e clearance between the cover an brake pe al, install inclu e brake pe al spacer
between frame an pe al in place of the thinner OEM spacer.
• 04-08 KX250F and 04-06 RMZ250:
You must use the inclu e gasket with the Rekluse clutch cover to provi e a equate clearance for
the Core EXP clutch—failure to o so will result in clutch amage. You must also install the
inclu e brake pe al spacer.

USER’S GUIDE
Doc ID: 193-297B
Doc Rev: 031111
©2011 REKLUSE All Rights Reserve
110 E. 43r Street
Boise, I aho 83714
208-426-0659
www.rekluse.com
[email protected]

Page 18
Overview
Thank you for purchasing the Rekluse Core EXP Clutch. We hope you enjoy the pro uct as much
as we enjoye esigning, testing an making the pro uct.
It is very important that you un erstan how to set your installe gap an check for a proper
installe gap using the free play gain metho . Settin , breakin -in and re-settin the installed
ap after installin new friction disks is CRUCIAL. Failure to properly maintain your installe
gap can result in premature wear or failure of your clutch.
Settin the Installed Gap
The installe gap allows the Core EXP clutch to automatically isengage the clutch at engine i le
spee . The installe gap is set with the pressure plate a juster. The pressure plate a juster has
two functions:
1. Lift an hol the pressure plate away from the clutch pack to create the installe gap
2. Provi e a surface for the clutch throw-out to push against to manually isengage the
clutch with the clutch lever
The pressure plate a juster threa s into the center of the pressure plate. Turning the pressure
plate a juster clockwise moves the pressure plate a juster towar s the center clutch nut.
Continuing to turn the pressure plate a juster clockwise after it makes contact with the center
clutch nut will lift the pressure plate creating the installe gap.
If the clutch is cable-actuate , start by increasing the free play in the clutch lever at the clutch
perch. The lever shoul come in freely at least half-way to the bar. No changes at the clutch lever
are necessary for a hy raulic clutch.
Loosen the 2 set screws in the pressure plate a juster that lock it in place. Insert the 5-mm hex
key into either of the two 5-mm hex holes in the pressure plate a juster an turn the pressure
plate a juster counter clockwise until it turns freely.

Page 19
Insert the long en of the 5-mm hex key into either of the two 5-mm hex holes. Turn the short en
of the hex key with your han clockwise to threa the pressure plate a juster inwar . Turn the
a juster until it comes to a stop with mo erate pressure. The object is not to turn the a juster as
har as you possibly can but to get the pressure plate a juster firmly seate against the center
clutch nut. This is the startin point.
To set the installe gap, you will nee to turn the pressure plate a juster the specifie amount
past the starting point. Rekluse recommen s an installe gap setting of 1 full turn + 2 tick marks.
Refer to the section Installed Gap Options (page 8) for more information on installe gap
settings.
After the installe gap is set, tighten the screws evenly in 3-4 steps until the tops of the set
screws are flush with or slightly below the top of the a juster. Do not over-tighten the set screws
or you may amage the threa s in the pressure plate a juster. It is not necessary to put threa
locking compoun onto the set screws.
Settin the Installed Gap with a Hot En ine
The installed ap should be set with the en ine cold. If you nee to reset your installe gap
after ri ing, allow the clutch to cool with the clutch cover off for at least 20 minutes before setting
the installe gap. If you must reset your installe gap with the engine hot, set the installe gap to
1 full turn + 0 tick mark. Be sure to reset the installe gap with the engine col when you are able
to.
If you are trying to “fine-tune” your installe gap setting, this can be one without waiting for the
engine to cool. You may move the pressure plate a juster in or out from the installe gap position
it was set to col . Be sure to keep track of your col setting an any a justments ma e hot so as
not to excee the recommen e installe gap range (see Installed Gap Options page 8).

Page 20
Checkin the Installed Gap
The installe gap can be checke at any time by verifying the free play ain. Checking for free
play gain at the start of each ri e is quick, easy an ensures the clutch plates will become fully
engage un er heavy loa preventing premature wear or failure of the clutch plates.
Clutch lever free play gain is create when the EXP friction isk expan s an lifts the pressure
plate an pressure plate a juster off the center clutch nut. By applying light pressure to the clutch
lever with your finger, the throw-out will rest against the pressure plate. When the engine is
revve , the EXP friction isk will expan an lift the pressure plate. With the light finger pressure
on the lever, the throw-out will move outwar , following the pressure plate, an the clutch lever
will move inwar slightly.
With the engine at i le, apply light inwar pressure with your finger on the clutch lever; enough
pressure to take up any slack but not enough to lift the pressure plate. While continuing to apply a
light inwar pressure on the clutch lever, rev the engine to at least 5000 RPM.
The clutch lever shoul move in slightly un er light finger pressure as the engine revs. This
movement is calle free play ain. Free play gain is your in icator that the pressure plate is
being lifte by the EXP friction isk, allowing the force of the clutch springs to be transferre to
the clutch pack.
With the recommen e installe gap setting an the engine at normal operating temperature, the
free play ain when measure at the en of the lever shoul be approximately 1/8” (3mm).
When the engine is very hot, there will be more free play gain.
IMPORTANT NOTE: if you ever suspect your clutch is slipping while ri ing, stop for a moment,
put the bike in neutral an check for free play gain. If you cannot etect free play gain, stop an
reset your installe gap.
If resetting your installe gap is not possible, ri e gently to get the bike home by re ucing
acceleration an staying in lower gears with higher RPM. Try not to “lug” the engine as this puts a
larger loa on the clutch.