Rekluse CoreManual TorqDrive Operation manual

©2017 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
customerservi[email protected]
INSTALLATION & USER’S GUIDE
The Rekluse CoreManual TorqDrive Clutch Kit
Doc ID: 191-7113080A
Revision: 080118

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TABLE OF CONTENTS
OVERVIEW ...................................................................................2
INSTALLATION TIPS....................................................................3
TOOLS NEEDED...........................................................................3
INCLUDED PARTS.......................................................................4
BIKE PREP & DISASSEMBLY......................................................5
INSPECT THE DAMPERS........................................................7
INSTALL HUBS.............................................................................8
INSTALL THE CLUTCH PACK ...................................................10
PRESSURE PLATE INSTALLATION..........................................13
MAINTENANCE...........................................................................17
Clutch wear .............................................................................17
Clutch parts.............................................................................18
Preventive Maintenance..........................................................18
NEED ADDITIONAL HELP?........................................................20
OVERVIEW
•This kit replaces the OE (Original Equipment) or “stock” core
clutch components including the center clutch hub and
pressure plate with high-quality billet components designed
for optimal operation specific to your bike.
•All 8 OE friction disks will be replaced with Rekluse
TorqDrive®Frictions, and all OE steel drive plates will be
replaced with Rekluse TEC drive plates.
•All 6 of the OE drive pins will be reinstalled.
•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.

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INSTALLATION TIPS
•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 allows for easy clutch access
and eliminates the need to drain oil.
•Use an air or electric impact wrench to remove the center
clutch nut. If one is not available, you can place the bike in
top gear and hold the rear brake while loosening the center
clutch nut with a socket and breaker bar.
•Channel-lock pliers work best to bend the tabs of the washer
up over the center clutch nut.
•Use clean, quality JASO-MA or JASO-MA2 certified
transmission oil for best performance.
TOOLS NEEDED
•8 mm socket
•27 mm socket
•Channel-lock pliers
•Hammer
•Torque wrench (in-lb & ft-lb, or
N-m)
•T-25 Torx bit (included with kit)
•Screwdriver

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INCLUDED PARTS
Item
Item Type
Qty
6
Pressure Plate
1
23
Clutch Cover
1
27
Outer Hub
1
31
Inner Hub
1
47
Pressure ring screws - T-25 Torx Screw
(T-25 Torx bit included)
6
65
Steel Drive Plate - .040” (1 mm)
2
63
Steel Drive Plate - .048” (1 mm)
8
69
TorqDrive Friction Disks
9
Visit Rekluse.com/support for a full parts fiche illustration
and part numbers.

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BIKE PREP & DISASSEMBLY
1.Lay the bike on its left side. Catch any fuel that might drain in
a suitable container.
2.Using a socket, remove the clutch cover bolts, then remove
the clutch cover.
3.Remove the OE parts named in the following diagram.

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4.Soak the TorqDrive®friction disks in new engine oil for 5
minutes. Make sure the friction disks are coated on both
sides.
NOTES:
•Be careful that the drive pins do not fall into the engine while
disassembling.
•Use a hammer and large screw driver to bend down the tabs
of the tab washer.

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5.Remove the center hub assembly from the bike. Make sure
the thrust washer is in place on the main shaft and not stuck
to the bottom of the center hub assembly.
INSPECT THE DAMPERS
The OE dampers inside the center hub assembly shrink due to
heat and use. Any movement between the dampers will shorten
the life of your clutch. Inspect the dampers before proceeding and
replace if necessary. Use the following instructions to inspect the
dampers.
1. Hold the center hub assembly
in your hands, then place your
thumbs on the inner hub by
the embossed part numbers.
2. Rotate the inner hub back and
forth inside the outer hub.
Rekluse recommends
replacing the dampers if you
feel any play between the two
hubs.

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INSTALL HUBS
1.If the dampers are in good condition, remove the 6 rubber
dampers from the OE center hub assembly.
2.Install the 6 OE rubber dampers and the Rekluse inner hub
onto the Rekluse outer hub.

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3.Install the new center hub assembly into the motorcycle.
Make sure the thrust washer is on the main shaft before
installing.
4.Reinstall the OE tab washer and center clutch nut torqueing
the nut to 50 ft-lb (68 N-m).
5.Using the channel-lock pliers, bend up both tabs of the tab
washer tightly around the nut. The tabs can be bent on the
straight sides or around the corners.

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6.Seat the 6 OE drive pins into the Rekluse hub.
INSTALL THE CLUTCH PACK
1.Install 1 of the .040” (1 mm) thick drive plates in the
orientation shown into the clutch basket. (All drive plates will
follow this orientation).
NOTE: Proper orientation of the drive plates is critical for optimal
clutch performance. If you install them backwards, the clutch will
still function but will lack proper modulation performance.

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NOTES:
•Align the drive pin notches in the TEC drive plate with the drive
pins on the hub when you install the drive plate into the
basket. Be sure that the drive pins are seated in the notches
and not in the bigger sections.
•ALL the TEC plates must be aligned in the drive pins notches
or damage may occur. The plates will not move when installed
correctly.

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2.On top of the steel drive plate, install the rest of the clutch
pack. The clutch pack number and order is based on the bike
model. This information is found in the attached Setup Sheet
located at the back of the manual. The following diagram is
an example of the installed clutch pack.
3.Reinstall the OE throw-out.
TorqDrive
friction disks
.040” (1 mm) Steel
drive plate - (First in)
.040” (1 mm)
Steel drive plate
(Last in)
.048” (1.2 mm)
Steel drive
plates

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PRESSURE PLATE INSTALLATION
1.Install pressure plate by indexing the pressure plate into the
slots in the hub.
2.Place the OE slider ring on the pressure plate with the “top”
marking facing up. (The top side is rounded and the bottom
edge is sharp.)
3.Install the OE Belleville spring onto the slider ring, with the
rounded dome side facing up. See pictures for reference.
NOTE: The outer edge of the Bellville spring will make contact
with the slider ring. If it does not, the Bellville spring is upside
down.

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4.Install the OE pressure ring followed by the Rekluse Pressure
Plate Screws.
NOTE: There are 3 possible settings on the OE pressure ring.
Rekluse recommends setting Y/II (4-strokes) or Y/II (2-strokes)
for optimum clamping force and performance. See the Setup
Sheet located at the back of the manual for more information.
DO NOT reuse the stock screws, or clutch cover interference will
occur! DO NOT over-torque the screws, or damage to the screw
heads will occur!
Incorrect – The Belleville
spring is upside down.
Correct – The Belleville
spring sits flat against the
slider ring.

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5.Torque the pressure ring screws to 55 in-lb (4.5 ft-lb) (6 N-
m).
6.Install the OE cover gasket onto the Rekluse clutch cover,
then install the cover onto the clutch.
7.Reinstall the clutch cover bolts in their proper location, then
lightly tighten the cover bolts in small increments in a star
pattern. Torque the cover bolts to OE specifications.
250/300 2 stroke 2017+ models:
•Use 6 OEM bolts and 1 Rekluse bolt. Your Rekluse
clutch cover kit comes with 1 longer bolt to replace a
shorter OEM bolt. Install 6 of the OEM bolts in their
original location and install the longer Rekluse bolt in the
lower right hand corner. See following pictures for
reference.
Failure to install the OEM clutch cover bolts back in there proper
location can result in damage to your motorcycle.

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250/300 2 stroke 2017+ models:
--Rekluse bolt
--OE bolts

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8.If your clutch cover has an oil fill plug and/or engine
inspection plug, reinstall the plug.
MAINTENANCE
Clutch wear
Rekluse clutches are built using high quality materials but do
wear based on the rider’s use, type of terrain, and natural wear
and tear.
•Clutch longevity and performance is greatly increased with oil
quality and other bike factors that reduce engine heat.
•Riding style, such as speed, engine RPM, and terrain can
also effect the life of the clutch.
•To keep your clutch performing at its best, perform regular
maintenance on your bike and clutch based on your riding
style.

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•The maintenance range is based on an average rider’s
moderate use. If you ride in extreme environments or riding
conditions, use the lower end of the range for best
performance.
Clutch parts
Inspect all of your clutch parts at regular intervals for signs of
wear or excessive heat, and replace components as necessary.
•The OE spring ring can be optimized based on the wear and
height of the clutch pack. See the attached Setup Sheet for
the specific clutch pack measurements.
•Repeat the break-in procedure anytime you replace the
frictions disks. Always soak new friction disks in fresh oil
before installing.
•Measuring the clutch pack
can help determine if the
components need replacing.
The clutch pack is measured
with the entire clutch pack
together. Include the friction
pad in the measurement.
•Disk inspection examples
are found in the following
section.
Preventive Maintenance
•Use clean, quality oil with the JASO-MA or JASO-MA2
certification for motorcycles for best performance.
•Keep up with regular oil changes as per the bike
manufacturer’s recommendations. Clutch performance and
longevity depend on oil quality.
•Change the oil filter and/or clean the oil screen with every oil
change.
Measure entire
clutch pack
including the
friction pad.

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•Disk inspection examples: When inspecting the clutch
pack, the following pictures can be used as a reference.
These are best viewed in color by viewing this install
document on our website at www.rekluse.com/support.
Drive Plates – If the clutch pack is getting high amounts of
heat, purple, blue, or black color can be seen on the drive
plate teeth. See pictures below. Not all drive plates look the
same and may look different than pictured.
Friction Disks – Due to the dark color of the friction material,
the friction disks will appear almost black as soon as they are
put in oil. During inspection, look for glazing of the friction
material. Glazing will appear shiny and feel like glass, even
after oil is cleaned from the friction disk. Not all friction disks
look the same and may look different than pictured.
Normal Heat
High Heat
(Blue)
Excessive Heat
(Black)
Normal Friction
Glazed Friction

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NEED ADDITIONAL HELP?
Website
www.rekluse.com/support
Frequently Asked Questions
www.rekluse.com/faq
Support Videos
www.rekluse.com/support/videos
Phone
[phone]
Technical Support
Contact Technical Support for questions related to product
installation, tuning, and performance.
Hours:
Monday thru Friday: 8:00 a.m. - 5:00 p.m.
Mountain Time zone
Email: [e-mail]
Customer Service
Contact Customer Service for additional product information,
orders, and returns.
Hours:
Monday thru Friday: 8:00 a.m. - 5:00 p.m.
Mountain Time zone
Email: customerservi[email protected]