Rekluse CoreManual TorqDrive, Installation & User Manual

Page 1: ... 2017 Rekluse Motor Sports Rekluse Motor Sports Inc customerservice rekluse com INSTALLATION USER S GUIDE The Rekluse CoreManual TorqDrive Clutch Kit Doc ID 191 7113080A Revision 080118 ...

Page 2: ...nal Equipment or stock core clutch components including the center clutch hub and pressure plate with high quality billet components designed for optimal operation specific to your bike All 8 OE friction disks will be replaced with Rekluse TorqDrive Frictions and all OE steel drive plates will be replaced with Rekluse TEC drive plates All 6 of the OE drive pins will be reinstalled If you install t...

Page 3: ...t wrench to remove the center clutch nut If one is not available you can place the bike in top gear and hold the rear brake while loosening the center clutch nut with a socket and breaker bar Channel lock pliers work best to bend the tabs of the washer up over the center clutch nut Use clean quality JASO MA or JASO MA2 certified transmission oil for best performance TOOLS NEEDED 8 mm socket 27 mm ...

Page 4: ...te 1 23 Clutch Cover 1 27 Outer Hub 1 31 Inner Hub 1 47 Pressure ring screws T 25 Torx Screw T 25 Torx bit included 6 65 Steel Drive Plate 040 1 mm 2 63 Steel Drive Plate 048 1 mm 8 69 TorqDrive Friction Disks 9 Visit Rekluse com support for a full parts fiche illustration and part numbers ...

Page 5: ...5 BIKE PREP DISASSEMBLY 1 Lay the bike on its left side Catch any fuel that might drain in a suitable container 2 Using a socket remove the clutch cover bolts then remove the clutch cover 3 Remove the OE parts named in the following diagram ...

Page 6: ... friction disks in new engine oil for 5 minutes Make sure the friction disks are coated on both sides NOTES Be careful that the drive pins do not fall into the engine while disassembling Use a hammer and large screw driver to bend down the tabs of the tab washer ...

Page 7: ...hrink due to heat and use Any movement between the dampers will shorten the life of your clutch Inspect the dampers before proceeding and replace if necessary Use the following instructions to inspect the dampers 1 Hold the center hub assembly in your hands then place your thumbs on the inner hub by the embossed part numbers 2 Rotate the inner hub back and forth inside the outer hub Rekluse recomm...

Page 8: ...13080A Doc Rev 080118 INSTALL HUBS 1 If the dampers are in good condition remove the 6 rubber dampers from the OE center hub assembly 2 Install the 6 OE rubber dampers and the Rekluse inner hub onto the Rekluse outer hub ...

Page 9: ...ure the thrust washer is on the main shaft before installing 4 Reinstall the OE tab washer and center clutch nut torqueing the nut to 50 ft lb 68 N m 5 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 ...

Page 10: ... 1 of the 040 1 mm thick drive plates in the orientation shown into the clutch basket All drive plates will follow this orientation NOTE Proper orientation of the drive plates is critical for optimal clutch performance If you install them backwards the clutch will still function but will lack proper modulation performance ...

Page 11: ...e with the drive pins on the hub when you install the drive plate into the basket Be sure that the drive pins are seated in the notches and not in the bigger sections ALL the TEC plates must be aligned in the drive pins notches or damage may occur The plates will not move when installed correctly ...

Page 12: ...order is based on the bike model This information is found in the attached Setup Sheet located at the back of the manual The following diagram is an example of the installed clutch pack 3 Reinstall the OE throw out TorqDrive friction disks 040 1 mm Steel drive plate First in 040 1 mm Steel drive plate Last in 048 1 2 mm Steel drive plates ...

Page 13: ...ider ring on the pressure plate with the top marking facing up The top side is rounded and the bottom edge is sharp 3 Install the OE Belleville spring onto the slider ring with the rounded dome side facing up See pictures for reference NOTE The outer edge of the Bellville spring will make contact with the slider ring If it does not the Bellville spring is upside down ...

Page 14: ...g Y II 4 strokes or Y II 2 strokes for optimum clamping force and performance See the Setup Sheet located at the back of the manual for more information DO NOT reuse the stock screws or clutch cover interference will occur DO NOT over torque the screws or damage to the screw heads will occur Incorrect The Belleville spring is upside down Correct The Belleville spring sits flat against the slider r...

Page 15: ... small increments in a star pattern Torque the cover bolts to OE specifications 250 300 2 stroke 2017 models Use 6 OEM bolts and 1 Rekluse bolt Your Rekluse clutch cover kit comes with 1 longer bolt to replace a shorter OEM bolt Install 6 of the OEM bolts in their original location and install the longer Rekluse bolt in the lower right hand corner See following pictures for reference Failure to in...

Page 16: ...Pg 16 Doc ID 191 7113080A Doc Rev 080118 250 300 2 stroke 2017 models Rekluse bolt OE bolts ...

Page 17: ...als but do wear based on the rider s use type of terrain and natural wear and tear Clutch longevity and performance is greatly increased with oil quality and other bike factors that reduce engine heat Riding style such as speed engine RPM and terrain can also effect the life of the clutch To keep your clutch performing at its best perform regular maintenance on your bike and clutch based on your r...

Page 18: ...ure anytime you replace the frictions disks Always soak new friction disks in fresh oil before installing Measuring the clutch pack can help determine if the components need replacing The clutch pack is measured with the entire clutch pack together Include the friction pad in the measurement Disk inspection examples are found in the following section Preventive Maintenance Use clean quality oil wi...

Page 19: ...n the drive plate teeth See pictures below Not all drive plates look the same and may look different than pictured Friction Disks Due to the dark color of the friction material the friction disks 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 frictio...

Page 20: ...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 ...