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REKLUSE MOTOR SPORTS
The Rekluse Core EXP Kit with Adjustable Slave Cylinder
OVERVIEW
•
This kit replaces the OEM core clutch components including the center clutch hub and pressure
plate with high-quality billet components designed for optimal operation specific to your bike.
•
All 8 OEM friction disks will be reused, but all OEM steel drive plates will be replaced with
Rekluse TEC drive plates. Also, only 6 of the 12 OEM drive pins will be reinstalled.
INSTALLATION &
USER'S GUIDE
Doc ID: 191-7704A
Doc Rev: 040919
©2014 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
12000 W Franklin Rd
Boise, Idaho 83709
208-426-0659
support@rekluse.com
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Summary of Contents for Rekluse Core EXP
- Page 1 • All 8 OEM friction disks will be reused, but all OEM steel drive plates will be replaced with Rekluse TEC drive plates. Also, only 6 of the 12 OEM drive pins will be reinstalled. ©2014 Rekluse Motor Sports Rekluse Motor Sports, Inc.
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Page 2: Inside This Document
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. Rekluse Factory Formulated Oil is a perfect complement to any OEM or aftermarket wet clutch. Visit www.rekluse.com... -
Page 3: Included Parts
Adjustable Slave Cylinder Assembly (bleed syringe included) Pressure Plate Bolt &Spring Assembly * Denotes parts assembled as part of EXP disk assembly Visit Rekluse.com/support for a full parts fiche illustration and part numbers. Rekluse Core EXP - Hydraulic Page 3... - Page 4 Leave the thrust washer installed in the basket. Inspect the friction disks for signs of heat or wear. Replace if they are burnt or worn. 4. Soak the EXP disk in engine oil for 5 minutes. Rekluse Core EXP - Hydraulic Page 4...
- Page 5 INSTALLATION orientation). 5. Install the Rekluse Center Clutch Hub, making sure the OEM thrust washer is in place. NOTE: Proper orientation of the drive plates is critical for optimal clutch performance. If you install them backwards, the clutch will still function but will 6.
- Page 6 9. Install the rest of the clutch pack, noting the 12. Install this pressure plate subassembly. number and order of plates shown. 13. Install the Rekluse pressure plate springs and torque the pressure plate bolts. Do not reuse the OEM springs! 10.
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Page 7: Slave Cylinder Installation
[#28.2]. ball bearing [#56] installed in the slave piston [#28.3] with a small amount of grease. When installing the Rekluse slave cylinder, make sure the ball does not come loose. NOTE: If you are installing this product on a KTM Freeride, please reference the included Slave Cylinder Appendix sheet for fitment instructions. - Page 8 Turn the adjuster screw back to the initial 19. Install the Rekluse slave cylinder on the bike position with the top O-ring visible. using these parts, ending with the banjo bolt. Compress the piston until it bottoms out. Repeat the process until there is no longer air escaping from the top port when the piston is compressed.
- Page 9 20. Optional: If you purchased the Rekluse Slave Guard accessory, install it now using the instructions in the kit. 23. Pump the clutch lever 3-5 times then hold it against the bar/grip. 21. Remove the cap and bladder from the clutch master cylinder and top off the clutch fluid.
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Page 10: Installed Gap Setting
TECH VIDEO entitled “How to Check Free Play Gain”. “Lever Free Play” is essentially the “slack” in the clutch lever before it starts actuating the clutch. Rekluse Core EXP - Hydraulic Page 10... - Page 11 The clutch lever should move in about 1/8” (3mm) toward the handlebar as The following steps explain two ways to check Free you rev the engine. Play Gain. One will use the rubber band that has Rekluse Core EXP - Hydraulic Page 11...
- Page 12 In 1st gear, accelerate moderately to approximately 5,000 RPMs and come to a stop—repeat this 5 times. Next, starting in 2nd gear, accelerate moderately to approximately 5,000 RPMs then come to a stop—repeat this 5 times. Rekluse Core EXP - Hydraulic Page 12...
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Page 13: Clutch Noise
Oil: 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. Rekluse Factory Formulated Oil is a perfect complement to any OEM or aftermarket wet clutch. -
Page 14: Exp Tuning Options
EXP. Properly seated pads will be secured in place once the EXP is reassembled. Operating the clutch without the pads in place will cause part damage or failure. Rekluse Core EXP - Hydraulic Page 14... - Page 15 Due to the KTM Freeride’s smaller OEM slave cylinder banjo bolt, the included thread insert needs to be installed into the Rekluse Adjustable Slave Cylinder. 1. Thread the insert into the Rekluse Adjustable Slave Cylinder, using needle-nose pliers, starting with the thread insert tang.
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