Clutch Cover Installation Guide - Rekluse Core EXP 2.0 Owner's Manual

Clutch Cover Installation Guide

Installation:
The Rekluse clutch cover provides clearance for all Rekluse clutch systems using either the OEM gasket
or o-ring. If the OEM o-ring or gasket is damaged it should be replaced to guarantee proper sealing.
Some models require spacing or adjustment of the brake pedal to gain clearance of the cover. See model
notes below for specific instructions.
Increased Oil Capacity:
The Rekluse clutch cover is slightly deeper than the stock cover, increasing the oil capacity of some
models very slightly. If your motorcycle or ATV uses a dip-stick, sight glass or oil-level check bolt, continue
to use the method described in the vehicle's owner's manual to fill to the proper oil level. If your vehicle's
owner's manual only specifies an oil amount, add 10cc (10ml) additional oil to the amount specified in the
manual.
Model Notes:
All Honda Models:
•
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. Ensure that the gap in the o-ring cord is
placed at the top-most (12 o' clock) position on the clutch cover.
CRF250X:
•
To utilized the oil feeding feature in the Rekluse clutch cover you must replace the OEM throw-out
assembly with the included 743-006 Rekluse throw-out assembly. If you do not use the Rekluse
throw-out assembly you will have clutch cover interference
KTM 400/450/505/530, Husaberg 390/450/570 FE, FX:
•
To provide adequate clearance between the cover and brake pedal tip, remove the OEM tip and
replace it with the included Rekluse tip using the provided hardware and thread lock. Your pedal
position will need to be lowered about ¼-inch (6-mm) to gain necessary cover clearance. The
Rekluse tip is taller to allow for this. Refer to your owner's manual for instructions about properly
adjusting brake pedal height.
KX250F/KX450F/KLX450F/YZ250 2 stroke:
•
To provide clearance between the cover and brake pedal, install included brake pedal spacer
between frame and pedal in place of the thinner OEM spacer.
04-08 KX250F and 04-06 RMZ250:
•
You must use the included gasket with the Rekluse clutch cover to provide adequate clearance for
the Core EXP clutch—failure to do so will result in clutch damage. You must also install the
included brake pedal spacer.
Page 16
Doc ID: 199-300
Manual Revision: 052711
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