INSTALLATION & USER S GUIDE

Transcription

1 REKLUSE MOTOR SPORTS The Rekluse EXP Clutch OVERVIEW INSTALLATION & USER S GUIDE Dc ID: Manual Revisin: This kit will replace sme f the OEM frictins and drive plates with the EXP disk. The OEM pressure plate springs will als be replaced with high quality Rekluse springs Rekluse Mtr Sprts Rekluse Mtr Sprts, Inc W. Franklin Rd. Bise, Idah supprt@rekluse.cm

2 INSIDE THIS DOCUMENT INSTALLATION CHECKING FREE PLAY GAIN BREAK-IN MAINTENANCE EXP TUNING OPTIONS & ENGAGEMENT SETTINGS TROUBLESHOOTING GUIDE INSTALLATION TIPS Be sure t use prper eye prtectin Laying the bike n its side makes it easier t wrk n the clutch and eliminates the need t drain the il Be sure t turn ff the gas, wrk in a ventilated area and be prepared t catch any gas that may drain frm vent tubes TOOLS NEEDED 8mm, 10mm scket (fr remving clutch cver and stck springs) 8mm, 10mm wrenches fr cable adjustment PARTS INCLUDED EXP Frictin Disk Assembly (including adjustment springs) Sme mdels may require Rekluse drive plates See Setup Sheet Rekluse Pressure Plate Springs See Setup Sheet Rekluse Rubber Band (fr checking clutch Free Play Gain )

3 EXP FRICTION DISK STOCK PRESSURE PLATE Diagram is representative. Nt all mdels will be cnfigured as abve. INSTALLATION 1. Sak the frictin pads f the EXP frictin disk in il fr at least 5 minutes. NOTE: If yu are missing the flat washer, it is prbably stuck t the backside f yur stck pressure plate. 2. Place the bike in 4 th r 5 th gear. If yur bike is carbureted turn the fuel ff. 3. Lay the mtrcycle n its left side. If yur bike is carbureted catch any gas that drains frm the verflw in a suitable cntainer. 4. Remve the stck springs, pressure plate, and clutch pack. NOTE: Sme f the frictin plates and steel drive plates will be re-installed. See setup sheet fr the prper clutch pack cnfiguratin. 5. Install clutch pack. See setup sheet fr prper cnfiguratin. 6. If remved, re-install OEM thrw-ut, needle bearing, and flat washer nt thrw-ut rd. See next diagram. NOTE: If yur bike has an OEM spacer ball between the thrw-ut and thrw-ut rd, it needs t be re-installed. 7. See setup sheet as sme mdels als require a spacer. 8. Install OEM pressure plate. 9. Install pressure plate springs (see setup sheet fr prper cnfiguratin), and OEM blts. 10. Install clutch cver and trque cver blts t value recmmended in yur bike s wner s manual. 11. Stand the bike up, supprting it n its kickstand r a center stand. Rekluse EXP Clutch Page 3

4 Remve Cable Slack 12. Adjust the clutch cable s there is n free play between clutch lever and clutch perch; this means the clutch lever shuld be held in place against the perch and nt mve freely. If the clutch lever still mves freely, remve all f the clutch cable slack until the clutch lever des nt mve freely. Use the adjuster at the clutch perch r the in-line cable adjuster t remve all cable slack. CHECK FREE PLAY GAIN 13. Free Play Gain is the increase f lever free play as the RPMs increase. This mvement is caused by the EXP disk expanding and lifting the pressure plate. Fr cable EXP prducts there will be n free play in the lever when the bike is ff r at lw RPM. As the RPMs increase Free Play Gain will add free play at the lever. The fllwing steps explain tw ways t check Free Play Gain. One will use the rubber band that has been included in the clutch kit and ne explains using yur hand. Place the bike in neutral, start the engine and let it warm up fr 2-3 minutes. 14. Rubber Band Methd: We recmmend that yu use this methd t find yur initial Free Play Gain s yu can see what it is. We recmmend als checking it by hand as explained in the next step s yu can check free play gain bth ways. Wrap the included rubber band arund the uter end f the handlebar grip and attach t the ball end f the clutch lever. See the fllwing three phts fr an example. 15. Hand Methd: Free play gain can als be checked by using yur hand and hlding light pressure n the lever. With the bike at idle, pull n the clutch lever lightly with a single finger s the lever free play is taken up, but the clutch is nt disengaged. While cntinuing t apply light pressure, rev the engine t at least 5000 RPM. The clutch lever shuld mve in 1/16-1/8 (1.5 3mm) under yur finger pressure as yu rev the engine. Rekluse EXP Clutch Page 4

5 Nte: If yu are nt getting the crrect lever mvement, see the Free Play Gain Trubleshting step belw. Free Play Gain Trubleshting 16. If the lever cmes in t far it will be difficult t fully verride the clutch and the bike may have excessive drag. This means the cable adjustment needs t be tightened further using the perch adjuster and in-line adjustment. If yu cannt feel and/r see enugh free play gain the clutch culd be slipping and may burn up. the cable adjustment needs t be lsened using the perch adjuster and in-line adjustment. CLUTCH BREAK IN 17. Rev cycles: Warm up the bike fr 2-3 minutes. With the bike in neutral and yur hand ff f the clutch lever, rev the engine 20 times t at least 5000 RPM, letting the engine return t idle between each cycle. This allws the EXP t break in. it is best t perfrm sme rll-n starts, withut using the clutch lever, in 1st and 2nd gear. In 1st gear, accelerate mderately t apprximately 5000 RPMs and cme t a stp repeat this 20 times. Next, starting in 2nd gear, accelerate mderately t apprximately 5000 RPMs then cme t a stp repeat this step 10 times. 20. Re-check free play gain at yur clutch lever and adjust if necessary at this pint. Yur clutch pack will expand as it gets ht during nrmal riding, s it is a gd idea t check yur freeplay gain after yur bike is warmed up befre each ride. NOTE: Checking free play gain is simple and takes less than a minute t perfrm. Fr maximum clutch life, take a mment t check fr free play gain at the start f every ride r if yu ever feel the clutch slipping. WARNING: DO NOT RIDE WITHOUT SUFFICIENT FREE PLAY GAIN. Yur clutch may seem t perate prperly but it is nt getting full clamping frce and may slip imperceptibly. This can lead t premature failure f the clutch and EXP frictin disk. 18. With the engine running, pull in the clutch lever and click the bike int gear. Slwly release the clutch lever. The bike shuld stay in place, perhaps with sme frward creep. If the bike creeps t much, t the pint f taking ff r stalling, the idle may be t high r the installed gap may be t small (t much free play gain). 19. Once yu have the bike idling with first gear engaged, slwly apply thrttle t begin mving. T break in the clutch cmpnents Bump-starting The Rekluse EXP clutch can be bumpstarted by adjusting the cable adjuster in until there is a small amunt f free play between the clutch lever and perch. This essentially turns the clutch back int a manual clutch; althugh at higher RPMs, the clutch lever will mve in tward the handlebar. With a small amunt f free play between the clutch lever and perch, bump-start the bike as yu nrmally wuld. Once the bike Rekluse EXP Clutch Page 5

6 is started, pull in the clutch lever and put the bike in neutral. With the bike in neutral and the engine running, adjust the cable adjuster ut until the prper free play gain is fund. MAINTENANCE - Maintain adequate free play gain, checking befre every ride and adjusting if necessary. - Inspect yur clutch parts every 40 hurs fr signs f wear r excessive heat, and replace cmpnents as necessary. Clutch Squeal and Chatter Althugh it is harmless, sme bike mdels may have squeal r chatter cming frm the clutch at lw RPM as it engages. Clutch squeal is caused by the clutch cmpnents vibrating as the clutch engages and can becme mre audible as the clutch gets ht. Fr bike mdels that tend t have clutch squeal r chatter here are sme recmmendatins t reduce r eliminate it: - Oil: Rekluse recmmends that yu have fresh, clean JASO-MA rated il fr best clutch perfrmance. Dirty r ld il can make the clutch mre likely t squeal r chatter. - Clutch Basket: Available fr sme mdels, a Rekluse clutch basket will eliminate clutch squeal and chatter in mst cases because it is precisin machined frm high quality material and includes lng-life clutch dampers. A clutch basket that is damaged r has wrn-ut dampers tends t increase squeal r chatter. - During EXP disassembly, il tensin may cause wedge pads t stick t the bases and disldge frm the wedge. If the base ramps appear t be in gd shape, these pads can be carefully re-inserted int the wedge pckets wtihut affecting EXP perfrmance. WEDGE - Cre EXP: Upgrading t Cre EXP gives yu the ptin t run anti-squeal x-rings that will reduce r eliminate clutch chatter and squeal. Cre EXP als has ther benefits including increased il flw and trque capacity, lnger life billet parts and stck-like lever feel. Changing the Installed Gap will NOT affect clutch squeal r chatter. PAD Rekluse EXP Clutch Page 6