Rekluse Core EXP 3.0 TorqDrive Installation & User Manual Download Page 18 | Manualshive

Page: 18 / 39

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Pg. 14

Doc ID: 191-7803A

Doc Rev: 011918

8. Reinstall the OE oil plug if it was removed during

disassembly.

9. Torque clutch cover bolts to OE specification.

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.

SET THE INSTALLED GAP AND

CHECK FREE PLAY GAIN

Reinstall clutch cover
gasket or O-ring

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Summary of Contents for Core EXP 3.0 TorqDrive

Page 1: ...Clutch Lever Optimization x 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 a...

Page 2: ...ve plates will also show signs of bluing or darkness Squeal Chirping noise under acceleration or take off Chatter Shutter Vibration or surge under acceleration as the clutch engages Drag When stopped...

Page 3: ...or OEM disks recommended Tall Bike gearing Replace wedges with a heavier set if the gearing is taller than stock High RPM slip No Free Play Gain Re adjust the installed gap and re check Free Play Gai...

Page 4: ...66 87 3 7 1 66 0 0 1 0 1 87 6 783 6 7 0 1 0 1 080 2 7 1 66 0 0 080 2 7 1 66 3 781 1 237 216 7 0 12 6 5 37 21 47 5 9 3 7 5 9 3 7 7254 5 9 5 7 21 6 7 6 9 6 3 7254 5 9 3 1 0 17 530 6 77 1 635 1 21 85 7 2...

Page 5: ...17 Rekluse Motor Sports Rekluse Motor Sports Inc customerservice rekluse com INSTALLATION USER S GUIDE Core EXP 3 0 TorqDrive Clutch Upgrade Kit for Hydraulic Motorcycles Doc ID 191 7803A Revision 041...

Page 6: ...AND CHECK FREE PLAY GAIN 14 Step 1 Set the installed gap 16 Step 2 Learn how to check Free Play Gain 17 Two Ways to Check for Free Play Gain 19 The Rubber Band Method 20 The Hand Method 22 Step 3 Bre...

Page 7: ...in disposable work gloves Read this entire document before performing any steps Lay the bike on its left side when replacing the clutch This makes the clutch work easier and eliminates the need to dra...

Page 8: ...Container Open ended Wrenches Each upgrade kit includes a set of TorqDrive friction disks steel drive plates an EXP disk and pressure plate springs Please refer to the Setup Sheet for a listing of in...

Page 9: ...Rev 011918 Pg 5 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 DI...

Page 10: ...set of steel plates a set of friction disks and an EXP disk The specifics of the clutch pack depends on the bike The height of the assembled clutch pack and specific information for each bike can be...

Page 11: ...iled machined or modified on the tangs Replace basket if necessary Failure to inspect the basket and replace if necessary could result in death serious injury and or property damage 3 Install ALL the...

Page 12: ...w frictions and steel drive plates Do not reuse the old clutch pack Some friction disks are marked with a small colored dot This mark is used for processing and can be ignored The orientation of the c...

Page 13: ...following picture for reference 4 Begin installing the Rekluse clutch pack starting with a steel drive plate 5 Continue installing the clutch pack according to installation order listed on the Setup...

Page 14: ...ation 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 3 Install the pressure plate subassembly 4 Place the pr...

Page 15: ...of a smoother clutch with a clutch lever pull about equal to OE b Gold springs will yield a more aggressive clutch with clutch pull slightly higher than OE Rekluse recommends installing silver spring...

Page 16: ...g 3 red and 3 gold will result in an in between setup 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...

Page 17: ...150 5 red springs 5 gold springs KTM 200 5 green springs 5 red springs Husky TC250 2010 2013 5 gold springs 5 silver springs 5 Insert the pressure plate bolts into the screw sleeves Do not reuse the O...

Page 18: ...embly 9 Torque clutch cover bolts to OE specification 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...

Page 19: ...e to the pressure plate which in turn drives the motorcycle forward The installed gap is what allows the auto function of the product to perform properly Setup break in and rechecking the installed ga...

Page 20: ...ith the bike standing up locate the adjuster screw in the center of the adjustable slave cylinder b With the O ring showing use a 4 mm hex key to turn the adjuster screw clockwise until it stops under...

Page 21: ...with Free Play Gain check for Free Play Gain then skip to Step 3 Break in the new clutch If Free Play Gain is new to you follow the instructions below to help you learn this important step You can al...

Page 22: ...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 The correct installed gap is verified by observing an...

Page 23: ...ttle Free Play Gain will cause the clutch system to burn up Optimal Free Play Gain yields 1 8 3 mm of clutch lever movement measured at the ball end of the lever This measurement at the lever correlat...

Page 24: ...e auto clutch can make your motorcycle appear to be in neutral when in gear even when the engine is running and clutch lever released Motorcycles equipped with a Rekluse auto clutch can move suddenly...

Page 25: ...e Free Play Gain e While still in NEUTRAL quickly rev the engine between 5 000 7 000 RPM 1 2 to throttle then let it return to idle Notice the movement in the clutch lever when the engine is revved Th...

Page 26: ...the engine oil b With the bike at idle apply enough pressure to the clutch lever to take up the initial free play slack in the clutch lever c While still in NEUTRAL continue to apply light pressure a...

Page 27: ...cause motor oil delivery failure which can result in motor failure serious injury or death Break in Procedure Number of times Rev Cycles 1 Place the bike in NEUTRAL Warm up the bike for 2 3 minutes 2...

Page 28: ...rts 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 Make necessary adjustments before proceeding 6 Without using the clutch l...

Page 29: ...fter break in Do not perform 3rd gear starts with this product Starting in 3rd gear will burn up the clutch and decrease the performance of this product in a short amount of time Step 4 Adjust the ins...

Page 30: ...h pack wears over time Refer to the following pictures and chart in the next section for additional adjustment information Make each adjustment in small increments 1 2 tick marks at a time After each...

Page 31: ...echeck Free Play Gain Clutch lever only moves slightly or does not move at all too little Free Play Gain Clutch slips Bike seems to lose power Installed gap is too large Turn the adjuster screw counte...

Page 32: ...essive wear or heat Replace as needed Refer to OE service manual Change oil inspect and clean oil screen Refer to OE service manual Measuring the clutch pack and or the EXP disk can help determine if...

Page 33: ...how signs of excessive heat 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 f...

Page 34: ...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 fr...

Page 35: ...mine if the components need replacing See the attached Setup Sheet for the specific clutch pack measurements Clutch noise Although it is harmless some bike models may have noise coming from the clutch...

Page 36: ...ling 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 The idle should not be so high as to move the bike forward in gear with...

Page 37: ...o remove the pin and spring 3 Remove the remaining 2 pins and springs from the same side of the EXP base 4 Drop a new spring into the spring slot on the base then add the turn pin 5 Push the turn pin...

Page 38: ...disassemble the EXP the Teflon pads may fall out or be stuck to the ramp surfaces of the EXP bases Take care to ensure all pads are correctly placed into wedge pockets using gentle pressure to avoid d...

Page 39: ...cal 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...

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