Rekluse CoreEXP 3.0 Installation Manual Download Page 1

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Rekluse Motor Sports, Inc.

[email protected]

INSTALLATION GUIDE

For Harley-Davidson Cable Actuated

Sportster

Doc ID: 191-6206A

Revision: 062818

Summary of Contents for CoreEXP 3.0

Page 1: ...2015 Rekluse Motor Sports Rekluse Motor Sports Inc customerservice rekluse com INSTALLATION GUIDE For Harley Davidson Cable Actuated Sportster Doc ID 191 6206A Revision 062818...

Page 2: ...CK 17 INSTALL THE PRESSURE PLATE 21 SET INSTALLED GAP 24 FINISH INSTALLATION 25 RESET THE LEVER FREE PLAY 28 CHECK FREE PLAY GAIN 29 Learn how to check Free Play Gain 29 Two Ways to Check for Free Pla...

Page 3: ...ate included Safety Information document before operating the vehicle with the product installed Read this entire document before performing any steps If you install this product for a customer or ano...

Page 4: ...end Wrench open end wrench 7 8 open end wrench Snap ring pliers Pliers 1 1 8 socket 1 3 16 socket Torque wrench Telescoping magnet Dental pick Shop bench press Conventional oven T27 Torx bit Impact g...

Page 5: ...vary 12 50 Retaining ring 1 27 Center clutch 1 67 Steel drive plates 040 1 mm 9 16 Lining plate 1 5 Pressure plate with bearing 1 88 Core EXP clutch spring kit 1 60 2 Pressure plate springs 6 31 Scre...

Page 6: ...shows signs of excessive wear DISASSEMBLE CLUTCH 1 Fully collapse the in line cable adjuster so that the clutch lever becomes very loose at the perch This removes the tension on the clutch cable durin...

Page 7: ...n the oil into a suitable container 5 Loosen the chain tensioner lock nut then turn the chain tensioner adjustment bolt counterclockwise until it spins freely 6 Shift the bike into 5th gear then remov...

Page 8: ...sm Set these aside 10 Use a flat blade screwdriver to turn the threaded stud clockwise to remove the nut Set it aside 11 Clear a space below the primary gasket cover to set the cover once it is remove...

Page 9: ...ing compressor tool onto the throw out rod 13 Use a 9 16 open ended wrench to hold the clutch tool shaft in place Slowly turn the compressor tool handle clockwise until the spring is compressed enough...

Page 10: ...discard the clutch spring retaining ring 15 Remove the OE clutch Belleville spring and pressure plate and set them on a workbench 16 Use a 9 16 open ended wrench to hold the clutch tool shaft in plac...

Page 11: ...leville spring from the pressure plate 18 Use snap ring pliers to remove the snap ring from the throw out assembly then remove the throw out assembly from the pressure plate 19 Remove the snap ring fr...

Page 12: ...remove the right hand thread crankshaft nut by turning it counterclockwise Set it aside 21 Remove the left hand thread center clutch nut by turning it clockwise to remove it Set it aside 22 Remove th...

Page 13: ...y in separate hands then firmly slide them off their respective shafts Carefully set this assembly on a work bench If the drive gear is difficult to remove from the stator due to the magnetism use bot...

Page 14: ...k from the clutch basket then separate the OE friction disks from the OE drive plates There will be 8 friction disks and 7 drive plates 26 Flip the basket assembly over on a workbench then use snap ri...

Page 15: ...se a shop bench press to press out the OE center hub from the clutch basket Note Check the OE basket bearings for any signs of excessive wear or float If the bearing appears worn replace it with a new...

Page 16: ...covering on your hands when handling the basket 3 Wearing protective covering on your hands remove the basket from the oven Immediately install the Rekluse center hub into the OE basket Use the press...

Page 17: ...ction disk Note Check that the OE frictions meet the minimum specifications before installing them into the clutch pack If OE frictions do not meet specifications replacements can be purchased from yo...

Page 18: ...plate Note If you bike s idle RPM has changed from stock meaning that it idles either higher or lower than the stock setting see the EXP Tuning Options section to determine the best EXP spring setting...

Page 19: ...ear and clutch assembly and firmly slide them onto their respective shafts 6 Place a primary wedge tool between the teeth of the drive gear and the clutch assembly gear This will allow you to tighten...

Page 20: ...facing up on top of the OE center clutch nut 9 While keeping the OE Belleville washer on the nut reinstall the center clutch nut onto the clutch shaft by turning it counterclockwise Torque to 70 ft l...

Page 21: ...of the Rekluse pressure plate aligning the plate teeth with the machined notches in the pressure plate 2 Install the OE throw out through the backside of the Rekluse pressure plate Note 1993 2003 Spo...

Page 22: ...Install the Rekluse pressure plate springs then install the screw sleeves Install the pressure plate screws into the screw sleeves 5 Torque the pressure plate bolts to 9 ft lb 12 N m 6 Reinstall the...

Page 23: ...e key slot on the back side of the case 8 Reinstall the OE primary case cover Note The easiest way to perform this step is by first aligning the shifter shaft with the primary case and sliding it on p...

Page 24: ...row out rod 2 Turn the OE throw out rod counterclockwise until you feel firm resistance This position is knows as the Starting Point 3 Firmly turn the OE throw out rod 1 turns counterclockwise past th...

Page 25: ...mechanism spring by pressing it onto the lock nut in the clutch actuating mechanism 2 Reinstall the gasket for the OE derby cover then install the derby cover Lightly applying grease to the o ring can...

Page 26: ...hat the lock nut on the chain tensioner is still loose Then turn the adjustment bolt on the chain tensioner clockwise until the drive chain has 3 8 to 1 2 of travel in it 6 Taking care to keep the adj...

Page 27: ...m 8 Insert a funnel into the inspection window and pour 1 quart of OE recommend oil into the primary chaincase 9 Reinstall the OE chain inspection cover gasket and inspection cover Torque the bolts t...

Page 28: ...lutch cable before it starts actuating the clutch Applying a light finger pressure will take up this slack 1 Expand the in line adjuster until the cable slack is between 1 16 and 1 8 at the lever perc...

Page 29: ...can cause failure or damage to this product Setting the correct installed gap is critical for clutch performance Learn how to check Free Play Gain If you are familiar with checking Free Play Gain che...

Page 30: ...lates to achieving the ideal installed gap Two Ways to Check for Free Play Gain The following steps explain 2 ways to check Free Play Gain One way uses the rubber band Rekluse includes in the clutch k...

Page 31: ...comfortable checking the Free Play Gain using the hand method BEFORE YOU BEGIN verify that the bike is in NEUTRAL before checking Free Play Gain Failure to do so may result in the bike lurching forwa...

Page 32: ...nd 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 position to detect the Free Play Gain e While still in NE...

Page 33: ...e bike in NEUTRAL start the engine and let it warm up for 2 3 minutes to idle down and warm up the engine oil b With the bike at idle apply enough pressure to the clutch lever to take up the initial f...

Page 34: ...ote Only the derby cover needs to be removed to tune or reset the installed gap Symptom Reason Solution Too much Free Play Gain Clutch lever moves in too far Clutch has excessive drag or stalls It is...

Page 35: ...or death Break in Procedure Number of times 1 Warm up the bike for 2 3 minutes With the bike in NEUTRAL and your hand off of the clutch lever rev the engine 10 times being sure to let it return to idl...

Page 36: ...ust the installed gap 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 Do n...

Page 37: ...an 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 based on an idle of RPM 1050 If your idle is hig...

Page 38: ...slot on the base then add the turn pin NOTE Lining up the slot in the pin with the tab in the EXP will align the pin in proper position for locking the pin 5 Push the turn pin in far enough to clear t...

Page 39: ...e 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 Take care to ensure all pads are cor...

Page 40: ...ike Refer to the Safety Information sheet for more information 1 Pull the lever tight against the handlebar 2 Wrap the Velcro safety strap around the lever and handlebar pull it tight then fasten it N...

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