Related Manuals for Rekluse Core EXP 3.0 KLX 230
Summary of Contents for Rekluse Core EXP 3.0 KLX 230
- Page 1 INSTALLATION & USER’S GUIDE KLX 230/250/300 Doc ID: 191-7704010A Revision: 103023 ©2023 Rekluse. All Rights Reserved. customerservice@rekluse.com...
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Page 2: Table Of Contents
TABLE OF CONTENTS OVERVIEW ................. 3 INSTALLATION TIPS ............3 TOOLS NEEDED ..............4 INCLUDED PARTS ............. 4 REMOVING THE OE CLUTCH ........... 5 ASSEMBLING THE CLUTCH PACK ........9 INSTALLING THE CLUTCH ..........10 SETTING THE INSTALLED GAP ........11 CHECKING FREE PLAY GAIN ......... -
Page 3: Overview
This kit will replace several OE (Original Equipment) components with high- quality Rekluse components. • The OE drive plates will be replaced with Rekluse thin plates. • The OE hub and pressure plate will be replaced with Rekluse precision billet components. -
Page 4: Tools Needed
• 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 5: Removing The Oe Clutch
REMOVING THE OE CLUTCH 1. Soak the Rekluse EXP in new oil for at least 5 minutes. Make sure it is coated on both sides. 2. If applicable, turn the fuel petcock to “OFF.” 3. Lay the bike on its left side. Catch any fluids that might drain into a suitable container 4. - Page 6 5. Remove the clutch cover bolts and the clutch cover. 6. Look at the inside of the cover. If it contains a damping plate like the one shown below, it must be removed. Failure to remove the damping plate from the clutch cover can result in engine damage.
- Page 7 8. Remove the hub nut and washer and pull out the clutch assembly. Make sure the thrust washer behind the clutch assembly does not stick to the clutch. If it does, put it back on the mainshaft. Remove the spring screws, hold-down plate, and springs.
- Page 8 10. Remove the clutch pack and separate the friction discs from the drive plates if the frictions will be reused. Doc ID: 191-7704010A Pg. 8 Doc Rev: 103023...
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Page 9: Assembling The Clutch Pack
ASSEMBLING THE CLUTCH PACK 1. Assemble the clutch pack and pressure plate onto the Rekluse hub according to the Setup Sheet at the end of this manual. Be careful to keep the clutch pack from coming off the hub. 2. Install 2 of the 6 supplied springs onto the hub, followed by the OE hold-down plate and 2 OE screws. -
Page 10: Installing The Clutch
INSTALLING THE CLUTCH 1. Install the clutch assembly into the bike. This may require rotating the plates to get the proper orientation. Be sure that the hub fully seats onto the shaft. Install the OE washer and nut and torque to OE spec. 2. -
Page 11: Setting The Installed Gap
If Free Play Gain is new to you, follow the instructions below. You can also view the video titled “How to Check Free Play Gain” on our website at www.rekluse.com/support/videos. Optimal Free Play Gain yields 1/8”-1/4” (3 mm-6 mm) of clutch lever movement, measured at the ball end of the lever. -
Page 12: Two Methods To Check Free Play Gain
Two Methods to Check Free Play Gain There are two ways to check for 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 13: The Hand Method
c) While holding the top end of the rubber band against the handlebar, stretch the band downward, and then loop it through itself. d) Pull the band through the loop, and then attach it to the outside end of the clutch lever. e) While still in NEUTRAL, quickly rev the engine between 5,000-7,000 RPM (1/2 to ¾... -
Page 14: Adjusting The Installed Gap
c) While still in NEUTRAL, continue to apply light pressure and quickly rev the engine between 5,000-7,000 RPM (1/2 to ¾ throttle), then let it return to idle. Notice the movement in the clutch lever when the engine is revved. This is your Free Play Gain. d) When the bike returns to idle, rev the engine between 5,000-7,000 RPM a second time to verify the Free Play Gain again. - Page 15 Adjust the Installed Gap Solution Symptom Reason • The clutch lever Tighten the cable: moves in too far Increase the length (too much Free of the in-line cable Play Gain) adjuster housing The installed until the correct • Clutch has gap is too amount of Free Play excessive drag or...
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Page 16: Tuning The Exp
TUNING THE EXP This kit includes multiple spring settings to adjust the engagement RPM of the EXP friction disk. The EXP friction disk comes preinstalled with the recommended “Medium” setting. See the included Setup Sheet for a chart of the available EXP spring configurations. -
Page 17: Breaking In The New Clutch
BREAKING 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 steps for breaking in your clutch and any time new friction disks, EXP bases, Teflon pads, or wedges are installed. - Page 18 5. Without using the clutch lever, accelerate moderately to approximately 5,000 RPM to fully lock up the clutch and come to a complete stop. Repeat 10 times. 10 roll-on starts Note: If the engine wants to stall or the creep is excessive, the idle may be too high or the installed gap may be too small.
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Page 19: Maintenance
To keep your clutch performing at its best, perform regular maintenance on your bike and clutch. Clutch Wear Rekluse clutches are built using high-quality materials but do wear based on the rider’s use, type of terrain, and natural wear and tear. To keep your clutch performing at its best, perform regular maintenance on your bike and clutch based on your riding style. -
Page 20: Clutch Parts
Clutch Parts • Regularly inspect and replace all clutch components showing signs of wear or excessive heat. Rekluse recommends inspecting after the first 10 hours of use, and then every 20 hours after that. • Measuring the clutch pack and the EXP disk can help... -
Page 21: Disk Inspection Examples
When inspecting the clutch pack, the following pictures can be used as a reference. These are best viewed in color by viewing this install document at: 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 22: Need Additional Help
NEED ADDITIONAL HELP? Website www.rekluse.com/support Phone (208) 426-0659 Monday thru Friday: 8 am – 5 pm Mountian Time Email customerservice@rekluse.com Doc ID: 191-7704010A Pg. 22 Doc Rev: 103023...
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