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Manual Revision: 041315 OVERVIEW This kit will replace some of the OEM frictions and drive plates with the EXP disk. The OEM pressure plate springs will also be replaced with high quality Rekluse springs. The OEM slave cylinder will be replaced with a Rekluse Adjustable Slave Cylinder.
INSTALLATION o SETTING THE INSTALLED GAP o CHECKING FREE PLAY GAIN o BREAK-IN o MAINTENANCE o EXP TUNING OPTIONS & ENGAGEMENT SETTINGS o SETUP SHEET (model specific) o TROUBLESHOOTING GUIDE INSTALLATION TIPS Be sure to use proper eye protection ...
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3. Remove the OEM clutch parts named in the BIKE PREP & following diagram. DISASSEMBLY 1. Soak the EXP disk in engine oil for 5 min. NOTE: Some of the OEM friction disks and OEM steel drive plates will be reused. See setup sheet for specific configuration.
Clutch Cover Gasket (FOR 08-11 KTM 450/505 SXF/XC-F ONLY) Pressure Plate Spring (See setup sheet) 60.X EXP Adjustment Spring * (extra adjustment springs are included, see setup sheet) Steel Drive Plate (FOR KTM 125/144/150 ONLY) Wedge Assembly * Adjustable Slave Cylinder Assembly (bleed tube included)
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4. Install the clutch pack with the EXP. See 6. Install the OEM pressure plate, Rekluse setup sheet for specific configuration. pressure plate springs* [#60], and OEM pressure plate bolts and washers. *Clutch pack representative only. See setup sheet for specific configuration.
9. Starting at the slave cylinder, remove the OEM parts named in the following diagram beginning with the banjo bolt. b. Compress the piston[#28.3] until it bottoms out. Rekluse EXP Clutch Page 6...
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NOTE: When compressing the piston, fluid can shoot out from the slave cylinder port. Be sure to wear eye protection. 11. Check that the ball bearing[#56] is still in place. Rekluse EXP Clutch Page 7...
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14. Remove the cap and bladder from the clutch 16. Pump the clutch lever 3-5 times then hold it master cylinder and top off the clutch fluid. against the bar/grip. Rekluse EXP Clutch Page 8...
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Air and fluid should come out of the bleed tube. Tighten the bleed port. NOTE: The “Installed Gap” is the space between the pressure plate and the EXP disk created by the adjustment at the slave cylinder. This gap is what allows the clutch to spin freely until the desired RPM is reached for it to engage.
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OEM cap and RPM. Free Play Gain is caused by the expansion bladder. of the EXP disk which lifts the pressure plate away from the throwout assembly. Optimal Free Play Gain yields 1/8” (3mm) of clutch lever movement, measured at the end of...
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Wrap the included rubber band around the outer end of the handlebar grip and attach it to the ball end of the clutch lever. See the following three photos. Rekluse EXP Clutch Page 11...
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20 times to at least 5000 RPM, letting the engine return to idle between each cycle. This allows the EXP to break 2. With the engine running, pull in the clutch lever and click the bike into gear. Slowly release the clutch lever.
A clutch basket that is damaged or has worn-out dampers tends to increase squeal or chatter. Core EXP: Upgrading to Core EXP gives you the option to run anti-squeal x-rings that will reduce or eliminate clutch chatter and squeal.
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