Rekluse Core EXP 3.0 TorqDrive Installation & User Manual
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Rekluse Core EXP 3.0 TorqDrive Installation & User Manual

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There are several crucial steps that must be understood and performed to ensure your Radius X clutch
will function properly. Failure to properly install, break-in and maintain your clutch components will
result in premature wear or failure.
New Friction Disk Break-In Procedure
Failure to follow the break-in procedure and oil filter inspection process could cause motor oil
delivery failure which can result in motor failure, serious injury, or death.
DO NOT install a new set of friction disks and ride without following the break in procedure and
oil screen inspection process found in the installation manual.
o Soak new friction disks in oil
o Install new friction disk and set the installed gap
o Check and verify free play gain
o Perform the break-in procedure found in the installation manual
o Follow the oil filter inspection process found in the installation manual
Clutch Lever Optimization
There are some brands of bikes that ship with stock adjustable reach levers. It is important
when setting up any adjustable reach lever to adjust the lever position first, and then adjust Free
Play Gain second. If you were to do it the other way around, you could alter the FPG setting
while changing the reach of the lever, which could cause poor performance and early clutch
wear.
Rekluse offers an adjustable reach lever upgrade for most cable actuated models. This optional
upgrade provides the user with the ability to optimize the clutch lever position for your hand size
and personal preference. This will maximize lever feel for each individual.
See the lever optimization section in the manual for more details.
Checking Free Play Gain
Check free play gain at the start of each ride. Details on how to check free play can be found in your
installation manual.
Understand how to properly check for free play gain
o Do not ride if you cannot verify free play gain
o Clutch may seem to work fine but could be slipping excessively
If you cannot detect free play gain, reset the installed gap
READ ME FIRST
Doc ID: 193-711A
Doc Revision: 021517

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Summary of Contents for Rekluse Core EXP 3.0 TorqDrive

  • Page 1 Rekluse offers an adjustable reach lever upgrade for most cable actuated models. This optional upgrade provides the user with the ability to optimize the clutch lever position for your hand size and personal preference.
  • Page 2 High RPM Slip – Occurs above half throttle while accelerating, as the engine RPMs raise little or no power is transmitted to the rear wheel resulting in a loss of forward drive causing excessive clutch heat *Rekluse troubleshooting chart located on back of this page* Doc ID: 193-707A...
  • Page 3 Change the oil if it’s not clean high quality JASO MA certified Transmission oil oil. Over-used oil may cause squeal or chatter Replace the basket and/or cushions if they are worn (Rekluse Squeal or Chatter basket recommended if available for your model)
  • Page 5 INSTALLATION & USER’S GUIDE Core EXP 3.0 TorqDrive Clutch ® Upgrade Kit for Hydraulic Motorcycles Doc ID: 191-7803A Revision: 041019 ©2017 Rekluse Motor Sports Rekluse Motor Sports, Inc. customerservice@rekluse.com...

  • Page 6: Table Of Contents

    TABLE OF CONTENTS OVERVIEW ................3 INSTALLATION TIPS ............3 TOOLS ................... 4 INCLUDED PARTS ............... 4 DISASSEMBLE THE CLUTCH ..........5 CLUTCH PACK INSTALLATION ........... 6 Notes for Clutch Pack Installation: ........8 PRESSURE PLATE INSTALLATION ........10 Pressure Plate Spring Information ........11 SET THE INSTALLED GAP AND CHECK FREE PLAY GAIN ..................

  • Page 7: Overview

    · Lay the bike on its left side when replacing the clutch. This makes the clutch work easier and eliminates the need to drain the oil. · For optimal clutch performance Rekluse recommends using fresh, clean oil that meets JASO-MA oil rating requirements. Rekluse offers Factory Formulated Oil™...

  • Page 8: Tools

    EXP disk, and pressure plate springs. Please refer to the Setup Sheet for a listing of included parts for your bike model. Or visit us at www.rekluse.com/support for a full parts fiche illustration and part numbers. Doc ID: 191-7803A Pg.

  • Page 9: Disassemble The Clutch

    DISASSEMBLE THE CLUTCH 1. Turn the fuel petcock to “OFF” if applicable. 2. Lay the bike on its left side. Catch any fuel that might drain in a suitable container. 3. Use an 8 mm socket to remove the clutch cover. Pg.

  • Page 10: Clutch Pack Installation

    4. Remove the following parts from the clutch. Set aside the old clutch pack. It will not be reused. · Pressure plate bolts · Lining plate · Pressure plate springs · EXP disk · Pressure plate · Clutch pack Pressure plate and lining plate Bolts and springs...
  • Page 11 Failure to inspect the basket and replace if necessary could result in death, serious injury, and/or property damage. Install ALL the Rekluse basket sleeves into the basket slots. Make sure the sleeve tabs sit against the inside the basket, then push the sleeves down until they contact the bottom of the tang slot.

  • Page 12: Notes For Clutch Pack Installation

    Note: When seated in the basket, the sleeves may stick slightly above or below flush with the top of the basket. This is normal. Install all the basket sleeves Notes for Clutch Pack Installation: · The clutch pack will be replaced with all new frictions and steel drive plates.
  • Page 13 · Some OE basket have “half slots” at the top of the basket tangs. Rekluse products require the entire clutch pack be installed into the MAIN (deeper) basket slots. Installing the clutch pack and EXP disk in the “half slots” will cause performance issues.

  • Page 14: Pressure Plate Installation

    1. Add a light film of oil between the lining plate and pressure plate (this will help the plates stick together for ease of installation). 2. Place the new steel lining plate onto the Rekluse pressure plate by lining up the index tabs and slots. Do not reuse the old lining plate.

  • Page 15: Pressure Plate Spring Information

    OE. b. Gold springs will yield a more aggressive clutch with clutch pull slightly higher than OE. Rekluse recommends installing silver springs for a more superior lever feel and better matched torque capacity to motor output.
  • Page 16 Be sure to alternate springs when using 3 red and 3 gold to keep even pressure on the clutch. Rekluse recommends installing gold springs for a more superior lever feel and better matched torque capacity to motor output.
  • Page 17 Bike Model Standard Light Beta 250 RR 3 red / 3 blue springs 6 red springs Beta 350 RR 6 blue springs 6 red springs KTM 450 6 blue springs 6 red springs 2007-2011 KTM 125/150 5 red springs 5 gold springs KTM 200 5 green springs 5 red springs...

  • Page 18: Set The Installed Gap And Check Free Play Gain

    8. Reinstall the OE oil plug if it was removed during disassembly. 9. Torque clutch cover bolts to OE specification. Reinstall clutch cover gasket or O-ring SET THE INSTALLED GAP AND CHECK FREE PLAY GAIN It is very important that you understand how to set the installed gap in your new clutch, and be able to verify the installed gap by checking Free Play Gain.
  • Page 19 The “installed gap” is the free space in the clutch pack when the EXP disk is disengaged (collapsed). This gap allows the clutch to spin freely until the engagement RPM is reached and the EXP disk expands to close the gap and apply pressure to the pressure plate, which in turn drives the motorcycle forward.

  • Page 20: Step 1: Set The Installed Gap

    Setting the installed gap and checking Free Play Gain is a 4- step process. It is important to follow each step to ensure that your new clutch functions as designed. Step 1: Set the installed gap Do not ride your bike without the adjusting the installed gap.

  • Page 21: Step 2: Learn How To Check Free Play Gain

    Free Play Gain is different from the “normal” free play you are used to with your stock clutch. With the Rekluse auto clutch, Free Play Gain is the result of the EXP disk expanding and lifting the pressure plate to engage the clutch.
  • Page 22 closes the installed gap. The amount of Free Play Gain you feel in the lever corresponds to the amount the pressure plate has been lifted by the EXP disk expansion. Checking Free Play Gain allows you to externally monitor the installed gap so you can know when to make an adjustment if the installed gap is too large or too small.

  • Page 23: Two Ways To Check For Free Play Gain

    Gain The following steps explain 2 ways to check Free Play Gain. One way uses the rubber band Rekluse includes in the clutch kit, and one uses your hand. You can use either method to check for Free Play Gain.

  • Page 24: The Rubber Band Method

    Free Play Gain. Failure to do so may result in the bike lurching forward, and loss of control and/or injury may result. A Rekluse auto-clutch can make your motorcycle appear to be in neutral when in gear, even when the engine is running and clutch lever released.
  • Page 25 c) While holding the top end of the rubber band against the handlebar, stretch the band downward, then loop it through itself. d) Pull the band through the loop, then attach it to the outside end of the clutch lever. This will take up the initial free play (slack) and put the lever in a...

  • Page 26: The Hand Method

    The Hand Method Use the hand method to check Free Play Gain before the start of every ride for optimum performance and longevity of your new clutch. a) Before you begin, place the bike in NEUTRAL, start the engine and let it warm up for 2-3 minutes to idle down and warm up the engine oil.

  • Page 27: Step 3: Break-In The New Clutch

    Step 3: Break-in the new clutch Once you install your new clutch, it is important to break it in. A series of roll-on starts are used to break in the clutch. Follow these procedures for breaking in your clutch and any time new friction disks, EXP bases, Teflon pads, or wedges are installed.
  • Page 28 4. With the bike idling in first gear, slowly apply throttle to begin moving. 5. Without using the clutch lever, accelerate moderately to 10 roll-on starts approximately 5,000 RPM to fully lock up the clutch and come to a complete stop. Repeat 10 times.

  • Page 29: Step 4: Adjust The Installed Gap And Recheck Free Play Gain

    Note: Your clutch pack will expand with heat, so final adjustment to Free Play Gain should be made when the bike is warm. Remember not to ride without sufficient Free Play Gain. 4 strokes only: It is normal for some clutch debris to be produced during break in.

  • Page 30: Free Play Gain Adjustments

    Tick marks are located on the slave cylinder, and an etch mark is on the screw. If you need to re-position the hex key, you can use these marks for reference. Continue to adjust the slave cylinder 1-2 tick mark at a time until optimal Free Play Gain is achieved.

  • Page 31: Maintenance

    Symptom Reason Solution · Clutch lever moves in too far (too Turn the adjuster much Free Play screw clockwise 1-2 Gain) marks to increase the installed gap and Installed gap · Clutch has decrease Free Play is too small excessive drag or Gain.
  • Page 32 · Oil recommendations can also be viewed under Tech Tips on our website at www.rekluse.com/support/videos/atv-mc-support-videos. · Inspect all of your clutch parts for signs of wear or excessive heat, and replace components as necessary. Clutch wear is dependent on the riders use.

  • Page 33: Disk Inspection Examples

    These are best viewed in color by viewing this install document from 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.
  • Page 34 Friction Disks – Due to the dark color of the friction material, the friction disks will appear almost black as soon as they are put in oil. During inspection, look for glazing of the friction material. Glazing will appear shiny and feel like glass, even after oil is cleaned from the friction disk.

  • Page 35: Troubleshooting

    For bike models that have noise, here are some recommendations to reduce or eliminate it: · Change the oil: Rekluse recommends that you have fresh, clean JASO-MA or JASO-MA2 rated oil for best clutch performance. Dirty or old oil can make the clutch more likely to squeal or chatter.

  • Page 36: Exp Tuning Options

    You can tune the engagement RPM of the EXP disk by changing the spring configuration. The EXP disk comes set with the recommended “Medium” setting from Rekluse. For other EXP tuning options, see the Setup sheet. To prevent freewheeling and maximize engine braking, set the idle so there is a slight amount of drag while the bike is idling in gear and warmed up.

  • Page 37: Changing The Exp Springs

    6. Flip the EXP friction disk over, and repeat on the other side depending on engagement preference. 7. If you need to disassemble the EXP disk, you can watch the video on our website under Tech Tips at www.rekluse.com/support/videos/atv-mc-support-videos. Pg. 33 Doc ID: 191-7803A Doc Rev: 011918...
  • Page 38 Note: To maintain even pressure, when using two different color spring sets, install one set of 3 on one side of the EXP and the remaining set of 3 on the other side. If you disassemble the EXP, the Teflon pads may fall out or be stuck to the ramp surfaces of the EXP bases.

  • Page 39: Need Additional Help

    Contact Technical Support for questions related to product installation, tuning, and performance. Technical Support 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. Customer Service hours: Monday thru Friday: 8:00 a.m.

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