Rekluse Core EXP 2.0 Owner'S Manual Download

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OWNER’S MANUAL

Doc ID: 791-001

Doc Rev: 11/14/2011

110 E. 43rd Street

Boise, Idaho 83714

208-426-0659

www.rekluse.com

Summary of Contents for Core EXP 2.0

Page 2: ...on Procedure 9 Set Clutch Lever Free Play and Check for Lever Free Play Gain 13 Clutch Break In 13 Resetting Installed Gap After Break In 13 EXP Tuning 14 Product Engagement Settings 15 Clutch Cover I...

Page 3: ...gages the Rekluse auto clutch not wheel speed It may be possible to reach very high speeds coming down a hill in a very low gear When throttle is applied the Rekluse auto clutch will engage suddenly I...

Page 4: ...break in Read the maintenance guide for more information Check for free play gain at the start of each ride Understand how to properly check for free play gain o Do not ride if you cannot verify free...

Page 5: ...free play gain Performing clutch break in Re setting the installed gap after break in Verifying proper free play gain Clutch Parts Diagram Installation Procedure Refer to the 191 7700B installation ma...

Page 6: ...onents as directed in this owner s manual Setting the installed gap for break in Checking free play gain Performing clutch break in Re setting the installed gap after break in Verifying proper free pl...

Page 8: ...makes it easier to work on the clutch and eliminates the need to drain the oil o Be sure to turn off the gas work in a ventilated area and be prepared to catch any gas that may drain from vent tubes...

Page 9: ...cable housing adjusters adjusted in as well 4 Place the bike in 4th or 5th gear If your bike is carbureted turn the fuel off 5 Lay the motorcycle on its left side if your bike is carbureted catch any...

Page 10: ...as shown below and install onto Rekluse center clutch You will install 7 stock frictions and 8 Rekluse drive plates starting and ending with a Rekluse drive plate NOTE Beta Owners Only Your clutch pa...

Page 11: ...nto the Rekluse pressure plate as shown below Index the teeth of the lining plate into the corresponding recesses in the Rekluse pressure plate 17 Install Rekluse pressure plate with lining plate onto...

Page 12: ...pressure Be sure your starting point is when the pressure plate adjuster stops on the center clutch nut 21 Cable actuated models only Check to make sure there is lever free play If the clutch lever is...

Page 13: ...lick the bike into gear Slowly release the clutch lever The bike should stay in place perhaps with some forward creep or tension on the chain Once you have the bike idling with first gear engaged slow...

Page 14: ...ure of the clutch disks including the EXP friction disk EXP Tuning Adjusting the engine idle speed to match your engagement setting is important and greatly affects the overall feel of how the EXP fri...

Page 15: ...KTM 250 300 SX XC XCW RMS 7736B 6 Red 3 Red 3 Blue 6 Blue KTM 250 SXF XC F XCFW RMS 7738B 3 Silver 3 Red 6 Red 3 Red 3 Blue Kawasaki KX250F RMS 7740B 3 Silver 3 Red 6 Red 3 Red 3 Blue Kawasaki KX450F...

Page 16: ...ing 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...

Page 18: ...e clutch pack to create the installed gap 2 Provide a surface for the clutch throw out to push against to manually disengage the clutch with the clutch lever The pressure plate adjuster threads into t...

Page 19: ...h with or slightly below the top of the adjuster Do not over tighten the set screws or you may damage the threads in the pressure plate adjuster It is not necessary to put thread locking compound onto...

Page 20: ...up any slack but not enough to lift the pressure plate While continuing to apply a light inward pressure on the clutch lever rev the engine to at least 5000 RPM The clutch lever should move in slight...

Page 21: ...thickness shrinks through wear or initial break in of the friction disks and or EXP components the installed gap will grow If the installed gap grows too far the EXP friction disk will not be able to...

Page 22: ...tch lever will be in a comfortable position while riding with the Core EXP clutch Because hydraulic clutches self adjust no change in lever position adjustment is typically necessary when Core EXP is...

Page 23: ...disk wear and the amount of clutch lever free play gain felt as the engine is revved By setting the installed gap smaller for example 1 turn 0 tick marks the clutch has more room for wear before the i...

Page 24: ...wear under hard use a perfect match for your Core EXP clutch When clutch plates are new they will break in and the clutch pack height will shrink substantially in the first 10 30 minutes of riding Bre...

Page 25: ...engine and clutch it can be annoying to the rider For bike models that tend to have clutch squeal Rekluse provides x rings to be installed at the base of the center clutch The x rings dampen the clutc...