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Summary of Contents for Rekluse Core EXP 2.0
- Page 1 OWNER’S MANUAL Doc ID: 791-001 Doc Rev: 11/14/2011 ©2011 REKLUSE All Rights Reserved 110 E. 43rd Street Boise, Idaho 83714 208-426-0659 www.rekluse.com tech@rekluse.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS SAFETY WARNINGS ..........................3 READ ME FIRST ............................4 Converting Core Manual to Core EXP 2.0 .................. 5 Overview ..............................5 Clutch Parts Diagram ........................... 5 Installation Procedure ........................... 5 Converting EXP to Core EXP 2.0 ....................6 Overview .............................. -
Page 3: Safety Warnings
Doc Revision: 081211 Since any Rekluse auto clutch will make your bike appear to be in neutral when in fact it is in gear, it can move suddenly and unexpectedly if the operator applies the throttle with the bike in gear. Do not apply excessive throttle to the bike until you are certain the transmission is in neutral. -
Page 4: Read Me First
0 tick mark and reset the installed gap after the ride with the engine cold Visit the Rekluse Core EXP Tech Web Site for More Information Videos, tutorials and tips to help you get the most out of your Core EXP clutch: www.rekluse.com/core- exp-tech. -
Page 5: Converting Core Manual To Core Exp 2.0
Refer to the 191-7700B installation manual contained in the 791-001 Core EXP Owner’s Manual. Complete all the steps in the 191-7700B installation manual with the following exceptions: In Step 7 you will be removing the Rekluse Core Pressure Plate and springs. •... -
Page 6: Converting Exp To Core Exp 2.0
You will be re-using your EXP friction disk • If you have a hydraulic clutch equipped model you will be installing your OEM throw-out. The Rekluse • adjustable throw-out used with the EXP system is not used with the Core EXP system Note: Be certain you understand the clutch pack configuration for your model. -
Page 7: Installation Guide
INSTALLATION GUIDE Doc ID: 191-7700C Doc Rev: 081211 ©2011 REKLUSE All Rights Reserved 110 E. 43rd Street Boise, Idaho 83714 208-426-0659 www.rekluse.com tech@rekluse.com... -
Page 8: Overview
• Removal of your stock pressure plate, clutch pack and center clutch • Installation of the Rekluse Core center clutch • Installation of Rekluse drive plates with 7 friction plates from the stock clutch pack (you will leave out 1 or 2 stock frictions, depending on model) •... -
Page 9: Clutch Assembly Diagram
If you are still unsure about installing the x-rings after perch. reading the User’s Guide, Rekluse NOTE: Some bikes may also need the inline recommends that you skip this step as they cable housing adjusters adjusted in as well. - Page 10 9. Install the Rekluse center clutch, with stock center clutch thrust washer behind it, onto the main shaft. 10. Install the Rekluse tab lock washer so the 2 pre-bent tabs index down into the 2 corresponding holes of the Rekluse center NOTE: Some models have a clutch boss clutch.
- Page 11 NOTE: If you are missing the flat washer, it is probably stuck to the backside of your stock pressure plate. 17. Install Rekluse pressure plate with lining plate onto the Rekluse center clutch. Hold the pressure plate and lining plate together...
- Page 12 NOTE: To accurately find the starting point you should turn the short end of a standard 5mm hex. Using the long end, or a tool with too much leverage won’t allow for proper feeling of the starting point. On hydraulic models you will feel slight resistance as you thread the adjuster in due to the hydraulic pressure.
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Page 13: Set Clutch Lever Free Play And Check For Lever Free Play Gain
24. Install the included Rekluse clutch cover re- using your OEM clutch cover gasket or o-ring. Clutch Break-In See appendix A at the end of this manual for 26. With the engine running, pull in the clutch specific instructions for installing the Rekluse lever and click the bike into gear. -
Page 14: Exp Tuning
3 on one side of the EXP and the remaining set of 3 on the other side. The EXP friction disk comes set with the recommended “Medium” setting from Rekluse. See following table for spring setting options by product number. -
Page 15: Product Engagement Settings
Product Engagement Settings Medium Make Bike Model Product Low Springs Springs High Springs Beta 350,400,450,520 RMS-7723B 6 Red 3 Red 3 Blue 6 Blue Gas Gas 250/300 RMS-7700B 6 Red 3 Red 3 Blue 6 Blue Honda CRF250R RMS-7712B 3 Silver 3 Red 6 Red 3 Red 3 Blue Honda... -
Page 16: Clutch Cover Installation Guide
A length of o-ring cord is provided with your cover as the OEM o-ring occasionally does not fit back into the Rekluse or OEM cover after removal. Place a dab of grease into the o-ring groove in four spots to hold the o-ring cord in the groove. Lay o-ring into groove around cover. Trim o-ring so that you have minimal gap between mating ends of o-ring. -
Page 17: User's Guide
USER’S GUIDE Doc ID: 193-297B Doc Rev: 031111 ©2011 REKLUSE All Rights Reserved 110 E. 43rd Street Boise, Idaho 83714 208-426-0659 www.rekluse.com tech@rekluse.com... -
Page 18: Overview
Overview Thank you for purchasing the Rekluse Core EXP Clutch. We hope you enjoy the product as much as we enjoyed designing, testing and making the product. It is very important that you understand how to set your installed gap and check for a proper installed gap using the free play gain method. -
Page 19: Setting The Installed Gap With A Hot Engine
To set the installed gap, you will need to turn the pressure plate adjuster the specified amount past the starting point. Rekluse recommends an installed gap setting of 1 full turn + 2 tick marks. Refer to the section Installed Gap Options (page 8) for more information on installed gap settings. -
Page 20: Checking The Installed Gap
Checking the Installed Gap The installed gap can be checked at any time by verifying the free play gain. Checking for free play gain at the start of each ride is quick, easy and ensures the clutch plates will become fully engaged under heavy load preventing premature wear or failure of the clutch plates. -
Page 21: Understanding The Installed Gap
1 full turn. After the new components are broken in, the installed gap must be reset. After break-in, Rekluse recommends the installed gap be set to 1 full turn + 2 tick marks. Page 21... -
Page 22: Clutch Lever Free Play Vs. Free Play Gain
Clutch Lever Free Play vs. Free Play Gain Clutch lever free play is the amount of free movement in the clutch lever before the clutch begins to disengage. For cable actuated clutches, lever free play is adjusted at the clutch perch. Hydraulic clutches typically have a built-in amount of free play and the clutch lever position is typically set with an adjuster between the lever and the plunger. -
Page 23: Installed Gap Options
Installed Gap Options Although Rekluse recommends an installed gap setting 1 full turn + 2 tick marks, there may be situations where you want to set your installed gap differently. The installed gap setting represents a trade-off between maintenance required for friction disk wear and the amount of clutch lever free play gain felt as the engine is revved. -
Page 24: Friction Plates And Wear
To minimize maintenance and maximize the durability of your clutch, we recommend Rekluse friction plates when your clutch pack has worn. Rekluse friction plates are OEM quality or better and are designed for minimum wear under hard use: a perfect match for your Core EXP clutch. -
Page 25: Spare Friction Disk Set
For bike models that tend to have clutch squeal, Rekluse provides x-rings to be installed at the base of the center clutch. The x-rings dampen the clutch vibrations to eliminate clutch squeal. However, x-rings will change the clutch lever modulation slightly;... - Page 26 ©2011 REKLUSE All Rights Reserved 110 E. 43rd Street Boise, Idaho 83714 208-426-0659 www.rekluse.com tech@rekluse.com...
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