Rekluse CoreEXP 3.0 User manual

©2015 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
customer[email protected]om
INSTALLATION GUIDE
For Harley-Davidson Cable Actuated
Sportster
Doc ID: 191-6206A
Revision: 062818

Pg. 2 Doc ID: 191-6206A
Doc Rev: 062818
Table of Contents
OVERVIEW ...................................................................................3
INSTALLATION TIPS....................................................................3
TOOLS...........................................................................................4
INCLUDED PARTS.......................................................................5
BEFORE YOU BEGIN...................................................................6
DISASSEMBLE CLUTCH..............................................................6
ASSEMBLE THE CLUTCH BASKET..........................................15
INSTALL THE CLUTCH PACK ...................................................17
INSTALL THE PRESSURE PLATE.............................................21
SET INSTALLED GAP ................................................................24
FINISH INSTALLATION..............................................................25
RESET THE LEVER FREE PLAY...............................................28
CHECK FREE PLAY GAIN .........................................................29
Learn how to check Free Play Gain........................................29
Two Ways to Check for Free Play Gain..................................30
The Rubber Band Method.......................................................31
The Hand Method....................................................................33
ADJUST THE INSTALLED GAP.................................................34
BREAK IN THE NEW CLUTCH...................................................35
EXP TUNING OPTIONS .............................................................37
Changing the springs..............................................................37
LEVER SAFETY STRAPS ..........................................................40
NEED ADDITIONAL HELP?........................................................40

Doc ID: 191-6206A
Doc Rev: 062818
Pg. 3
OVERVIEW
This kit replaces the OE (Original Equipment) or “stock” clutch
pack.
•This kit will replace all the OE drive plates, pressure plate, the
pressure plate springs and screws, and the inner clutch hub.
Do not dyno test this product without reviewing the
included dynamometer document.
•This kit includes extra EXP springs, which can be used to
tune for your desired engagement. See the EXP tuning
options section in this document for specific tuning
information.
INSTALLATION TIPS
•Read the separate included Safety
Information document before operating
the vehicle with the product installed.
•Read this entire document before
performing any steps.
•If you install this product for a customer or another person,
instruct them to read the Safety Information document and
the Installation and User Guide before operating the bike
with the product.
•Videos related to this product can be viewed online at
www.rekluse.com/support/videos.
•Protect eyes and skin – wear safety glasses and work gloves.
Work in a well ventilated area.
•Use the torque values listed in the instructions. Otherwise, use
the torque specifications found in your OE service manual.
•Visit www.rekluse.com/support for a full parts fiche illustration
and part numbers.

Pg. 4 Doc ID: 191-6206A
Doc Rev: 062818
TOOLS
•¼” hex key
•5/16” hex key
•3/16” hex key
•5 mm hex key
•5/32” hex key
•5/8” open-end wrench
•9/16” open-end Wrench
•½” open-end wrench
•7/8” open-end wrench
•Snap ring pliers
•Pliers
•1 1/8” socket
•1 3/16” socket
•Torque wrench
•Telescoping magnet
•Dental pick
•Shop/bench press
•Conventional oven
•T27 Torx bit
•Impact gun
•Flat head screwdriver
Additional tools available for purchase at a local dealership:
•Primary wedge tool
•Clutch spring removal tool

Doc ID: 191-6206A
Doc Rev: 062818
Pg. 5
INCLUDED PARTS
Item Description Qty.
13 EXP bases 2
85
Wedge assembly
6
51
Quarter-turn pins (extra included)
8
60.1 EXP adjustment springs – colors vary 12
50 Retaining ring 1
27 Center clutch 1
67 Steel drive plates - .040” (1 mm) 9
16 Lining plate 1
5 Pressure plate with bearing 1
88 Core EXP clutch spring kit 1
60.2 Pressure plate springs 6
31 Screw sleeves 6
47 Socket head cap screws 6
Not shown Throw-out spacer 1
Not shown Velcro straps 2
Not shown
Orange Free Play Gain rubber band
1
Not shown Clutch lever warning label 1

Pg. 6 Doc ID: 191-6206A
Doc Rev: 062818
BEFORE YOU BEGIN
•Rekluse recommends replacing the chaincase cover gasket
when installing this product.
•The OE basket bearing may need to be replaced if it shows
signs of excessive wear.
DISASSEMBLE CLUTCH
1.Fully collapse the in-line cable adjuster, so that the clutch lever
becomes very loose at the perch. This removes the tension on
the clutch cable during disassembly and installation.
2.Soak the EXP disk in new primary transmission
oil for 5 minutes. Make sure the EXP is coated
on both sides.
3.Stand the bike up on a suitable bike stand or lift.

Doc ID: 191-6206A
Doc Rev: 062818
Pg. 7
4.On the primary chain case, use a 5/8” wrench to remove the
oil drain plug, then drain the oil into a suitable container.
5.Loosen the chain tensioner lock nut, then turn the chain
tensioner adjustment bolt counterclockwise until it spins
freely.
6.Shift the bike into 5th gear, then remove the shift lever off its
shaft and set it aside.
7.Remove any footboards that block the primary case and set
them aside.

Pg. 8 Doc ID: 191-6206A
Doc Rev: 062818
8.Remove the derby cover and the O-ring gasket.
9.Remove the spring and the jam nut from the actuating
mechanism. Set these aside.
10.Use a flat blade screwdriver to turn the threaded stud
clockwise to remove the nut. Set it aside.
11.Clear a space below the
primary gasket cover to set
the cover once it is removed.
Remove the primary case
cover and the cover gasket.
Note: The attached clutch cable
limits where you can set the
primary cover when it is removed.

Doc ID: 191-6206A
Doc Rev: 062818
Pg. 9
12.Hand thread the clutch spring compressor tool onto the
throw-out rod.
13.Use a 9/16” open-ended wrench to hold the clutch tool shaft
in place. Slowly turn the compressor tool handle clockwise
until the spring is compressed enough to remove the snap
ring.
The spring is loaded. Wear eye protection.

Pg. 10 Doc ID: 191-6206A
Doc Rev: 062818
14.Use a pair of pliers to remove and discard the clutch spring
retaining ring.
15.Remove the OE clutch Belleville spring and pressure plate
and set them on a workbench.
16.Use a 9/16” open-ended wrench to hold the clutch tool shaft
in place. Slowly turn the clutch tool handle
counterclockwise until it spins freely.

Doc ID: 191-6206A
Doc Rev: 062818
Pg. 11
17.Unthread the clutch tool from the throw-out rod and remove
it, then separate the Belleville spring from the pressure
plate.
18.Use snap ring pliers to remove the snap ring from the throw-
out assembly, then remove the throw-out assembly from the
pressure plate.
19. Remove the snap ring from the throw-out rod.
Note: Set aside the OE Belleville spring, OE pressure plate, and
the OE snap rings. They will not be reused.

Pg. 12 Doc ID: 191-6206A
Doc Rev: 062818
20.Using an impact gun and socket, remove the right hand
thread crankshaft nut by turning it counterclockwise. Set it
aside.
21.Remove the left hand thread center clutch nut by turning it
clockwise to remove it. Set it aside.
22.Remove the small Belleville washer that is located behind
the center clutch nut.

Doc ID: 191-6206A
Doc Rev: 062818
Pg. 13
23. Remove the drive gear, clutch assembly, and chain
simultaneously. All three parts must be removed as one
unit.
•Do this by grasping the drive gear and clutch assembly in
separate hands, then firmly slide them off their respective
shafts. Carefully set this assembly on a work bench.
•If the drive gear is difficult to remove from the stator due
to the magnetism, use both hands to initially begin sliding
it off of the shaft before removing it as a unit.
24. Separate the drive gear from the clutch assembly by sliding
the chain off of each indexing gear and setting aside.

Pg. 14 Doc ID: 191-6206A
Doc Rev: 062818
25.Remove the clutch pack from the clutch basket, then
separate the OE friction disks from the OE drive plates.
There will be 8 friction disks and 7 drive plates.
26. Flip the basket assembly over on a workbench, then use
snap ring pliers to remove the center hub retaining ring. Set
it aside.

Doc ID: 191-6206A
Doc Rev: 062818
Pg. 15
ASSEMBLE THE CLUTCH BASKET
1.Use a shop/bench press to press out the OE center hub from
the clutch basket.
Note: Check the OE basket bearings for any signs of excessive
wear or float. If the bearing appears worn, replace it with a new
OE unit available at your local dealership.
OE Basket
OE Center Hub

Pg. 16 Doc ID: 191-6206A
Doc Rev: 062818
2.Preheat a conventional oven to 350°F (175°C), then place the
OE basket in the oven for 15 minutes.
The basket will be HOT! Be sure to wear protective covering
on your hands when handling the basket.
3.Wearing protective covering on your hands, remove the
basket from the oven. Immediately install the Rekluse center
hub into the OE basket. Use the press if needed to press the
hub into the basket. Let the basket cool.
Note: This thermal fit may allow for the Rekluse center hub to
slide into the basket bearing without the need of a press.

Doc ID: 191-6206A
Doc Rev: 062818
Pg. 17
4.After the basket has cooled, flip the basket over and install
the included Rekluse 35 mm retaining ring into the groove on
the Rekluse center hub.
INSTALL THE CLUTCH PACK
1.Install a Rekluse steel drive plate 1st into the clutch basket,
then install an OE friction disk.
Note: Check that the OE frictions meet the minimum
specifications before installing them into the clutch pack. If OE
frictions do not meet specifications, replacements can be
purchased from your local dealer.
•Minimum allowable thickness = 0.0835” (2.12 mm)
2.Continue to alternate Rekluse steel drive plates with OE
friction disks.
Rekluse steel drive
plate – 1
st
in
OE friction disk
Alternate Rekluse steel drive plates with OE frictions
Total Clutch Pack
9 steel drive plates
8 OE friction disks

Pg. 18 Doc ID: 191-6206A
Doc Rev: 062818
3.Install the EXP disk on top of the last steel drive plate.
Note:
•If you bike’s idle RPM has changed from stock – meaning
that it idles either higher or lower than the stock setting – see
the EXP Tuning Options section to determine the best EXP
spring setting before installing the EXP disk.
4.Re-index the chain onto the drive gear and clutch assembly.

Doc ID: 191-6206A
Doc Rev: 062818
Pg. 19
5.Install the drive gear, clutch assembly, and chain at the same
time. Do this by grasping the drive gear and clutch assembly
and firmly slide them onto their respective shafts.
6.Place a primary wedge tool between the teeth of the drive
gear and the clutch assembly gear. This will allow you to
tighten the nuts.
7.Reinstall the OE crankshaft nut by turning it clockwise, then
torque the nut to 240-260 ft-lb (325-353 N-m) per OE
specifications.

Pg. 20 Doc ID: 191-6206A
Doc Rev: 062818
8.Reinstall the OE Belleville washer with the cup-side facing
up on top of the OE center clutch nut.
9.While keeping the OE Belleville washer on the nut, reinstall
the center clutch nut onto the clutch shaft by turning it
counterclockwise. Torque to 70 ft-lb (94 N-m). Be sure to
keep the washer indexed as you tighten the nut.
10.Remove the wedge tool.