Rekluse CoreManual Operation manual

©2020
Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[e-mail]
INSTALLATION & USER’S
GUIDE
CoreManual Kit
for Sherco 250/300 2T (17+)
Doc ID: 191-7008001A
Revision: 08/07/20

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Table of Contents
OVERVIEW ...................................................................................2
INSTALLATION TIPS ....................................................................2
TOOLS...........................................................................................3
INCLUDED PARTS .......................................................................4
DISASSEMBLE CLUTCH..............................................................5
INSTALL THE HUB .......................................................................9
INSTALL THE CLUTCH PACK ...................................................11
INSTALL THE CLUTCH COVER ................................................15
BREAK IN ....................................................................................15
MAINTENANCE...........................................................................15
NEED ADDITIONAL HELP?........................................................16
OVERVIEW
This kit replaces OE (Original Equipment) or “stock” core clutch
components including the center clutch hub and pressure plate
with high-quality billet components designed for optimal
performance specific to your bike.
·All OE steel drive plates & friction disks will be replaced with
ones provided by Rekluse.
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 vehicle
with the product.
·Protect eyes and skin –wear safety glasses and work gloves.

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·Lay the bike on its left side when replacing the clutch. This
makes working on the clutch easier and eliminates the need
to drain the 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.
·For optimal clutch performance Rekluse recommends using
fresh, clean oil that meets JASO-MA oil rating requirements.
Rekluse offers Factory Formulated Oil™ developed
specifically for Rekluse products. Rekluse Factory
Formulated Oil is a perfect complement to any OEM or
aftermarket wet clutch. Visit www.rekluse.com to learn more.
·Use the torque values listed in the instructions. Otherwise,
use the torque specifications found in your OE service
manual.
TOOLS
8, 10, & 30
mm Sockets
Hex Keys
Metric
Wrenches
Torque
Wrench
Picks
Fluid Catch
Container
Hammer &
Flat Chisel
Channel-lock
pliers
5mm

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INCLUDED PARTS
Item
Description
Qty.
6
Pressure plate
1
27
Center clutch hub
1
30
Lock-tab washer
1
67
Steel drive plate - .048” (1.2mm)
thick and .060”
9
69
OE-style friction disk (3mm thick)
8
88
Core clutch spring assembly
1
60
Pressure plate springs
6
31
Screw sleeves
6
47
Socket head cap screws
6
Visit www.rekluse.com/support for a full parts fiche illustration and part numbers.

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DISASSEMBLE CLUTCH
1.If your bike is carbureted, turn the fuel
petcock to “OFF.”
2.Shift the transmission into 5th gear.
3.Lay the bike on its left side. Catch any draining fuel using a
suitable container.
4.Using an 8 mm socket, remove the OE clutch cover. Pay
close attention to the length and location of the OE screws so
they can each be returned to the same location.
5.Using a socket, remove the pressure plate screws and
springs, then remove the pressure plate.
Note: Your OE parts may look different than pictured depending
on the bike.

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6.Remove the OE clutch pack. Use a pick if necessary to help
remove all of the plates.
7.Remove the throw-out assembly, which typically includes a
throw-out, needle bearing, and washer. Set this assembly
aside. These parts will be reused.
Note: The throw-out assembly may look different depending on
the bike.

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8.Use a hammer and a large screwdriver or chisel to bend
down the edges of the washer tab until it clears the clutch nut.
9. Remove the center clutch nut with an impact wrench or
breaker bar, and a socket. Set aside. The OE clutch nut will
be reused.
Note: Placing the bike in the highest gear and holding the rear
wheel by applying the rear brake keeps the shaft from rotating
when removing the nut.
10. Remove the lock washer located under the center clutch
nut. The OE lock washer will be replaced with a Rekluse tab
lock washer.

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11. Remove the center hub from the clutch basket while leaving
the thrust washer on the main shaft.
Note: Check that the OE thrust washer is still on the main shaft
and not stuck to the bottom of the center hub assembly. The
thrust washer must be installed or clutch performance issues will
result.
Thrust
washer

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12. Inspect the clutch basket for spring damper play or
notching. Do not install product with a notched basket.
Notched basket tang faces or worn dampers can cause the
friction plates to break. Do not use baskets that have been
filed, machined, or modified on the tangs. Replace basket if
necessary.
Failure to inspect the basket and replace if necessary could
result in death, serious injury, and/or property damage.
INSTALL THE HUB
1.Check to make sure the OE thrust washer is still on the main
shaft.
2.Install the new Rekluse center hub into the clutch basket.

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3.Install the new Rekluse tab washer with the bent tabs facing
down, aligning with the holes in the hub. Only use the
supplied lock tab washer under the OE center clutch nut
when installing the hub.
4.Install the OE center clutch nut.
5.Using the socket and torque wrench, torque the center clutch
nut to 50 ft-lb (68 N-m).
Rekluse tab
lock washer
OE clutch nut

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Note: Placing the bike in the highest gear and holding the rear
wheel by applying the rear brake keeps the shaft from rotating
when tightening the nut.
6.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.
INSTALL THE CLUTCH PACK
1.Soak the provided friction disks in new oil for at least 5
minutes.

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Clutch Pack Cross-section Overview
2.Install the clutch pack starting with a .048in (1.2mm) steel
drive plate, then install one of the provided friction disks.
Then install 1 .060in (1.52mm) drive plate.
3.Continue to alternate friction disks and .060in (1.52mm) steel
drive plates.
4.The last plate installed will be a .048in (1.2mm) drive plate
Alternate steel drive plates with friction disks
Friction disk
Steel drive plate –Install 1st
Pressure plate
Steel drive plate
.048in (1.2mm)
OE style friction
disk
Steel drive plate
.048in (1.2mm)
OE style friction
disk
Steel drive plate

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5.Reinstall the OE throw-out assembly (including the bearing
and washer). If the throw-out washer is missing, check to see
if it is stuck to the underside of the pressure plate.
6.Install the pressure plate.

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7.Install the Rekluse pressure plate springs, followed by the
screw sleeves and socket head cap screws.
Do not reuse the OE springs, washers, or bolts!
Note: If two different spring colors are provided with your kit, be
sure to alternate the springs by color in every other pocket to
keep even pressure on the clutch.
*Heavier springs options are available from Rekluse if desired*
8.Use a torque wrench and socket to torque the cap screws by
lightly tightening the screws in small increments. Torque the
cap screws to 9 ft-lb (12 N-m).
9.With the pressure plate screws torqued, pull the clutch lever a
few times to ensure proper function of the hydraulic clutch
system. If everything functions well, move on to the next
section.
Note: If you feel abnormal resistance when pulling clutch lever
(i.e. it does not travel all the way to the handlebar) then it is
likely that the OE throwout rod has worn enough to change the
optimal spacing of the slave cylinder piston. Remove the
circlip from the OE throwout assembly and install the included
throwout washer between the throwout assembly and the
pressure plate. This will return the spacing to normal.

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INSTALL THE CLUTCH COVER
1.Place the Rekluse clutch cover onto the bike, then reinstall
the OE bolts into the clutch cover. Be sure to return the bolts
to the same locations from which they were removed.
Failure to install the OE clutch cover bolts back in their
proper location can result in damage to your motorcycle.
BREAK IN
Break-in will occur over the first 1-2 hours of use, depending on
the rider. During break-in more clutch drag may occur than
normal.
MAINTENANCE
·Inspect all of your clutch parts at regular maintenance
intervals for signs of wear or excessive heat, and replace
components as necessary. Clutch wear is very dependent on
the riders use, inspection interval may vary.
·Keep up with regular oil changes and other bike
maintenance. For optimal clutch performance Rekluse
recommends using fresh, clean oil that meets JASO-MA oil
rating requirements. Clutch longevity and performance is
greatly increased with oil quality and other bike factors that
reduce engine heat.
·Replace friction disks regularly for best clutch component life,
especially if they appear glazed and/or burnt upon inspection.

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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: [email protected]
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: [e-mail]