Rekluse CoreManual Installation & User Manual
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Rekluse CoreManual Installation & User Manual

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INSTALLATION & USER'S
GUIDE
CoreManual Kit
for Sherco 250/300 2T (17+)
Doc ID: 191-7008001A
Revision: 08/07/20
©2020 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
customerservice@rekluse.com

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Summary of Contents for Rekluse CoreManual

  • Page 1 INSTALLATION & USER’S GUIDE CoreManual Kit for Sherco 250/300 2T (17+) Doc ID: 191-7008001A Revision: 08/07/20 ©2020 Rekluse Motor Sports Rekluse Motor Sports, Inc. customerservice@rekluse.com...

  • Page 2: Table Of Contents

    · All OE steel drive plates & friction disks will be replaced with ones provided by Rekluse. INSTALLATION TIPS · Read the separate included Safety Information document before operating the vehicle with the product installed.

  • Page 3: Tools

    · Channel-lock pliers work best to bend the tabs of the washer up over the center clutch nut. · For optimal clutch performance Rekluse recommends using fresh, clean oil that meets JASO-MA oil rating requirements. Rekluse offers Factory Formulated Oil™ developed specifically for Rekluse products.

  • Page 4: Included Parts

    .060” OE-style friction disk (3mm thick) Core clutch spring assembly Pressure plate springs Screw sleeves Socket head cap screws Visit www.rekluse.com/support for a full parts fiche illustration and part numbers. Doc ID: 191-7008001A Pg. 4 Doc Rev: 080720...

  • Page 5: Disassemble Clutch

    DISASSEMBLE CLUTCH 1. If your bike is carbureted, turn the fuel petcock to “OFF.” 2. Shift the transmission into 5 gear. 3. Lay the bike on its left side. Catch any draining fuel using a suitable container. 4. Using an 8 mm socket, remove the OE clutch cover. Pay close attention to the length and location of the OE screws so they can each be returned to the same location.
  • Page 6 6. Remove the OE clutch pack. Use a pick if necessary to help remove all of the plates. 7. Remove the throw-out assembly, which typically includes a throw-out, needle bearing, and washer. Set this assembly aside. These parts will be reused. Note: The throw-out assembly may look different depending on the bike.
  • Page 7 10. Remove the lock washer located under the center clutch nut. The OE lock washer will be replaced with a Rekluse tab lock washer. Doc ID: 191-7008001 Pg.
  • Page 8 11. Remove the center hub from the clutch basket while leaving the thrust washer on the main shaft. Note: Check that the OE thrust washer is still on the main shaft and not stuck to the bottom of the center hub assembly. The thrust washer must be installed or clutch performance issues will result.

  • Page 9: Install The Hub

    INSTALL THE HUB 1. Check to make sure the OE thrust washer is still on the main shaft. 2. Install the new Rekluse center hub into the clutch basket. Doc ID: 191-7008001 Pg. 9 Doc Rev: 080720...
  • Page 10 3. Install the new Rekluse tab washer with the bent tabs facing down, aligning with the holes in the hub. Only use the supplied lock tab washer under the OE center clutch nut when installing the hub. 4. Install the OE center clutch nut.

  • Page 11: Install The Clutch Pack

    Note: Placing the bike in the highest gear and holding the rear wheel by applying the rear brake keeps the shaft from rotating when tightening the nut. 6. Using the channel-lock pliers, bend up both tabs of the tab washer tightly around the nut. The tabs can be bent on the straight sides or around the corners.
  • Page 12 Clutch Pack Cross-section Overview Pressure plate Steel drive plate .048in (1.2mm) OE style friction disk OE style friction disk Steel drive plate .048in (1.2mm) 2. Install the clutch pack starting with a .048in (1.2mm) steel drive plate, then install one of the provided friction disks. Then install 1 .060in (1.52mm) drive plate.
  • Page 13 5. Reinstall the OE throw-out assembly (including the bearing and washer). If the throw-out washer is missing, check to see if it is stuck to the underside of the pressure plate. 6. Install the pressure plate. Doc ID: 191-7008001 Pg. 13 Doc Rev: 080720...
  • Page 14 7. Install the Rekluse pressure plate springs, followed by the screw sleeves and socket head cap screws. Do not reuse the OE springs, washers, or bolts! Note: If two different spring colors are provided with your kit, be sure to alternate the springs by color in every other pocket to keep even pressure on the clutch.

  • Page 15: Install The Clutch Cover

    INSTALL THE CLUTCH COVER 1. Place the Rekluse clutch cover onto the bike, then reinstall the OE bolts into the clutch cover. Be sure to return the bolts to the same locations from which they were removed. Failure to install the OE clutch cover bolts back in their proper location can result in damage to your motorcycle.

  • Page 16: 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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