Rekluse EXP Installation instructions

Doc ID: 193-300A
Revision: 121718
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©2018 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
[email protected]
The Rekluse EXP assembly is built using high quality
materials, however, it does experience natural wear and tear
like any clutch component. The amount of wear is based on
the rider’s use and type of terrain.
It is important to inspect the EXP assembly at regular
intervals for signs of wear, including the internal ramps and
wedges.
Symptoms of wear may include:
•The clutch either slips or stalls even with Free Play
Gain adjusted correctly
•The clutch excessively drags
•It is difficult to find the proper Free Play Gain
adjustment
INSPECTION SCHEDULE
The EXP assembly should be inspected using the following
schedule. The “Light” inspection range is based on an
average rider’s moderate use.
The “Heavy” inspection range is based on riding in extreme
environments or riding conditions.
Bike Model
Clutch Use
Light Heavy
Dirt / Off-Road 40-50 hours 20-30 hours
Adventure / Dual
Sport
8,000-15,000 miles 3,000-5,000 miles
Street 10,000-20,000 miles 5,000-8,000 miles
EXP ASSEMBLY INSPECTION

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INSPECT EXP ASSEMBLY
Use the following instructions to properly inspect the EXP
bases, wedges, and Teflon pads.
Step 1: Remove the EXP assembly
a.Remove the EXP assembly from the bike. Instructions
for disassembling the clutch can be found in your
installation manual.
b.Clean off any debris or oil from the EXP bases with a
clean towel.
Step 2: Measure the EXP
a.Measure the width of the EXP assembly from friction pad
to friction pad. Use the part number stamped on the EXP
base tab to determine which measurement is correct for
your bike model.
•For EXP part number 140-216: minimum thickness
is .590” (14.99 mm).
•For all other part numbers: minimum thickness is
.416” (10.57 mm).
b.If the EXP is above the minimum thickness, continue
with the next step. If the EXP is below the minimum
thickness, replace the EXP bases and Teflon pads.
Measure from friction pad
to friction pad.

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Step 3: Test the wedges
a.Push a pair of wedges (opposite from each other) from
the inside of the EXP assembly toward the outside of the
assembly.
b.Release the wedges once they have reached the outside
edge of the assembly. The wedges should move easily
and spring back in place without catching once released.
•If all the wedges in the EXP assembly spring back,
continue with the next step.
•If one or more of the wedges stick, the EXP bases and
Teflon pads may need to be replaced. Continue with
the next step for further inspection.
Push and release
wedge pairs

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Step 4: Visually inspect EXP
•Inspect the EXP assembly for any evidence of
hammering on the tabs. A hammered tab is when one of
the EXP base tabs has been compressed and is
narrower than the other tab. If the EXP tab wear is more
than .020” (.5 mm), the EXP assembly needs to be
replaced.
oKTM / Husqvarna DDS models:
If the hammering is less than .020” (.5 mm), the
EXP assembly can be flipped over to extend the
life of the EXP. If any amount of hammering is
present, inspect the inner hub and dampers for
signs of wear in addition to inspecting the EXP
assembly. Replace the dampers in the hub
assembly if there is rotational play as well as the
EXP assembly.
oFor traditional clutch models:
If hammering is present, inspect the clutch basket
dampers in addition to inspecting the EXP
assembly.
c.Inspect the EXP for signs of damage.
Hammered
tab

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•A damaged tab is when the EXP tab(s) have visible
signs of damage. If there are any signs of damage,
replace the EXP bases.
d.Check that all the friction pads on both sides of the EXP
assembly are still bonded onto the bases. If any of them
are missing, replace the EXP bases.
e.Check the friction pads for glazing. Due to the dark color
of the friction pad material, the pads will appear almost
black as soon as they are put in oil.
•A normal friction pad will still have a rough finish
even though the pads are black.
Missing
friction pad
Normal friction pad

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•In contrast, glazing will appear shiny and feel like
glass, even after oil is cleaned from the friction pads.
If the friction pads are glazed, replace the EXP
bases.
f. Inspect both sides of the EXP assembly for signs of
discoloration.
•Light staining may be caused by the oil and the EXP
may still function properly.
Light staining
Glazed friction pad

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•Heavy staining may indicate high heat from the clutch,
and the bases and wedges may need to be replaced.
g.Once the visual inspection is complete, continue with the
next step.
Step 5: Disassemble the EXP assembly
a.Using a flat-blade screwdriver, push the ¼ turn pin in far
enough to clear the opposite side of the EXP to unlock
the pin.
b.With the pin still pushed past the base, turn ¼ of a turn
to remove the pin and spring. Remove all the remaining
pins and springs the same way.
Heavy staining

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c. Separate the bases and remove the wedges. Be aware
that Teflon pads may stick to base ramps from oil tension.
Just remove the stuck pads from the EXP base and set
them aside before continuing to inspect the bases.
Step 6: Inspect the ramps
a.Inspect all the ramps that are located inside of both EXP
bases. Replace the EXP bases and Teflon pads if there
is any evidence of a raised outline on the ramp, or if the
ramp has an indentation. See the following examples.
EXP ramps
for inspection

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Normal - Ramps with machine marks or look
shiny/polished are normal. These can be reused.
Machine marks
Shiny or polished
Damaged - Ramps that have a raised outline (burr)
or have an indentation are damaged and need to be
replaced.
Raised mark (burr) Indentation
NOTE: If you replace the EXP bases, it is HIGHLY
RECOMMENDED that you replace the Teflon pads or
wedges as well for best performance.

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Step 7: Inspect the wedges
a.Inspect all the Teflon pads in the wedges. The pads
should stick slightly above the edge of the wedge pocket.
If the pads sit flush or below the edge of the pocket,
replace the pads.
NOTE: If a Teflon pad has
fallen out during
disassembly, press the pad
back into the wedge pocket
using the flat side of a
screwdriver.
Do not press directly in the center of the pad with the tip
of the screwdriver or with any sharp object. This will
make an indent in the pad and the wedge will not
function properly.
b.Inspect the pads for damage. The pads should be smooth
with no nicks, cuts, or imbedded debris.
•If the Teflon pads are good, continue with the next
step.
•If the Teflon pads are worn or damaged, the Teflon
pads need to be replaced. A kit is available through
Rekluse.
Pads should
be slightly
above the

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Step 8: Reassemble the EXP bases
a.Place all of the wedges onto one of the EXP bases, then
place the second base on top of the wedges. Make sure
the wedges have all their Teflon pads in place.
b.Reinstall 3 of the EXP springs, then reinstall the quarter
turn pins. If you have two different color springs, only
install one color of spring on each side.
c.Flip the EXP over and reinstall the remaining springs
and quarter turn pins.
d.Once assembled, push each pair of wedges out from the
inside of the EXP to make sure the wedges move freely.
NOTE: The EXP assembly might have a small gap down the
center line once reassembled. The gap may not be even or
symmetrical. This gap will close during the break-in
procedure.
e.Reassemble the clutch pack and then break-in the new
EXP bases, wedges, and/or Teflon. Break-in directions
can be found in your installation manual or on our
website.
f. Re-check Free Play Gain before riding.
NEED HELP?
Visit our website at www.rekluse.com/support or call us at
[phone].