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Summary of Contents for Rekluse CoreManual TorqDrive
- Page 1 INSTALLATION & USER’S GUIDE The Rekluse CoreManual TorqDrive Clutch Kit Doc ID: 191-7113080A Revision: 080118 ©2017 Rekluse Motor Sports Rekluse Motor Sports, Inc. customerservice@rekluse.com...
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Page 2: Table Of Contents
• 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. -
Page 3: Installation Tips
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. •... -
Page 4: Included Parts
(T-25 Torx bit included) Steel Drive Plate - .040” (1 mm) Steel Drive Plate - .048” (1 mm) TorqDrive Friction Disks Visit for a full parts fiche illustration Rekluse.com/support and part numbers. Pg. 4 Doc ID: 191-7113080A Doc Rev: 080118... -
Page 5: Bike Prep & Disassembly
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. Doc ID: 191-7113080A Pg. - Page 6 ® 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. •...
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Page 7: Inspect The Dampers
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. Doc ID: 191-7113080A Pg. -
Page 8: Install Hubs
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. Pg. 8... - Page 9 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.
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Page 10: Install The Clutch Pack
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). - Page 11 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. •...
- Page 12 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.
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Page 13: Pressure Plate Installation
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. - Page 14 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.
- Page 15 5. Torque the pressure ring screws to 55 in-lb (4.5 ft-lb) (6 N- 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.
- Page 16 250/300 2 stroke 2017+ models: --OE bolts --Rekluse bolt Pg. 16 Doc ID: 191-7113080A Doc Rev: 080118...
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Page 17: Maintenance
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. -
Page 18: Clutch Parts
• 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. - Page 19 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.
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Page 20: Need Additional Help
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: tech@rekluse.com Customer Service Contact Customer Service for additional product information, orders, and returns. Hours: Monday thru Friday: 8:00 a.m. - 5:00 p.m.
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