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Rekluse CoreManual, Installation & User Manual

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Rekluse CoreManual Installation & User Manual Download Page 12

Pg. 12 

Doc ID: 191-7008001A 

Doc Rev: 080720

 

 

 

Clutch Pack Cross-section Overview 

 

2. Install the clutch pack starting with a .048in (1.2mm) steel 

drive plate, then install one of the provided friction disks. 
Then install 1 .060in (1.52mm) drive plate. 

 

3. Continue to alternate friction disks and .060in (1.52mm) steel 

drive plates.  

 

4. 

The last plate installed will be a .048in (1.2mm) drive plate

 

 

 

Alternate steel drive plates with friction disks 

Friction disk 

Steel drive plate 

–

 Install 1

st

  

Pressure plate 

Steel drive plate 

.048in (1.2mm) 

OE style friction 

disk 

Steel drive plate 

.048in (1.2mm)  

 

OE style friction 

disk 

Steel drive plate 

Summary of Contents for CoreManual

Page 1: ... 2020 Rekluse Motor Sports Rekluse Motor Sports Inc customerservice rekluse com INSTALLATION USER S GUIDE CoreManual Kit for Sherco 250 300 2T 17 Doc ID 191 7008001A Revision 08 07 20 ...

Page 2: ...ality billet components designed for optimal performance specific to your bike All OE steel drive plates friction disks will be replaced with ones provided by Rekluse INSTALLATION TIPS Read the separate 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 anot...

Page 3: ... the tabs of the washer up over the center clutch nut 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 to learn more Use the torque values...

Page 4: ...lutch hub 1 30 Lock tab washer 1 67 Steel drive plate 048 1 2mm thick and 060 9 69 OE style friction disk 3mm thick 8 88 Core clutch spring assembly 1 60 Pressure plate springs 6 31 Screw sleeves 6 47 Socket head cap screws 6 Visit www rekluse com support for a full parts fiche illustration and part numbers ...

Page 5: ...ide Catch any draining fuel using a suitable container 4 Using an 8 mm socket remove the OE clutch cover Pay close attention to the length and location of the OE screws so they can each be returned to the same location 5 Using a socket remove the pressure plate screws and springs then remove the pressure plate Note Your OE parts may look different than pictured depending on the bike ...

Page 6: ...se a pick if necessary to help remove all of the plates 7 Remove the throw out assembly which typically includes a throw out needle bearing and washer Set this assembly aside These parts will be reused Note The throw out assembly may look different depending on the bike ...

Page 7: ... clutch nut with an impact wrench or breaker bar and a socket Set aside The OE clutch nut will be reused Note Placing the bike in the highest gear and holding the rear wheel by applying the rear brake keeps the shaft from rotating when removing the nut 10 Remove the lock washer located under the center clutch nut The OE lock washer will be replaced with a Rekluse tab lock washer ...

Page 8: ... clutch basket while leaving the thrust washer on the main shaft Note Check that the OE thrust washer is still on the main shaft and not stuck to the bottom of the center hub assembly The thrust washer must be installed or clutch performance issues will result Thrust washer ...

Page 9: ...cause the friction plates to break Do not use baskets that have been filed 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 INSTALL THE HUB 1 Check to make sure the OE thrust washer is still on the main shaft 2 Install the new Rekluse center hub into the clutch basket ...

Page 10: ... facing down aligning with the holes in the hub Only use the supplied lock tab washer under the OE center clutch nut when installing the hub 4 Install the OE center clutch nut 5 Using the socket and torque wrench torque the center clutch nut to 50 ft lb 68 N m Rekluse tab lock washer OE clutch nut ...

Page 11: ...ng the rear brake keeps the shaft from rotating when tightening the nut 6 Using the channel lock pliers bend up both tabs of the tab washer tightly around the nut The tabs can be bent on the straight sides or around the corners INSTALL THE CLUTCH PACK 1 Soak the provided friction disks in new oil for at least 5 minutes ...

Page 12: ...install 1 060in 1 52mm drive plate 3 Continue to alternate friction disks and 060in 1 52mm steel drive plates 4 The last plate installed will be a 048in 1 2mm drive plate Alternate steel drive plates with friction disks Friction disk Steel drive plate Install 1st Pressure plate Steel drive plate 048in 1 2mm OE style friction disk Steel drive plate 048in 1 2mm OE style friction disk Steel drive pla...

Page 13: ...oc Rev 080720 Pg 13 5 Reinstall the OE throw out assembly including the bearing and washer If the throw out washer is missing check to see if it is stuck to the underside of the pressure plate 6 Install the pressure plate ...

Page 14: ...ightening the screws in small increments Torque the cap screws to 9 ft lb 12 N m 9 With the pressure plate screws torqued pull the clutch lever a few times to ensure proper function of the hydraulic clutch system If everything functions well move on to the next section Note If you feel abnormal resistance when pulling clutch lever i e it does not travel all the way to the handlebar then it is like...

Page 15: ...rag may occur than normal MAINTENANCE Inspect all of your clutch parts at regular maintenance intervals for signs of wear or excessive heat and replace components as necessary Clutch wear is very dependent on the riders use inspection interval may vary Keep up with regular oil changes and other bike maintenance For optimal clutch performance Rekluse recommends using fresh clean oil that meets JASO...

Page 16: ...426 0659 Technical Support Contact Technical Support for questions related to product installation tuning and performance Hours Monday thru Friday 8 00 a m 5 00 p m Mountain Time zone Email tech rekluse com Customer Service Contact Customer Service for additional product information orders and returns Hours Monday thru Friday 8 00 a m 5 00 p m Mountain Time zone Email customerservice rekluse com ...

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