REKLUSE MOTOR SPORTS The Rekluse Cre EXP Kit OVERVIEW INSTALLATION & USER S GUIDE Dc ID: 191-7743A Dc Rev: 083116 This kit replaces the OEM cre clutch cmpnents with high-quality billet cmpnents designed fr ptimal peratin specific t yur bike mdel. When this installatin is perfrmed, the bike s basket assembly will be disassembled and then reassembled using the Rekluse basket. This Rekluse basket is taller than the OEM ne and is a necessary cmpnent t achieve verall clutch perfrmance and imprve the life f the clutch basket. NOTE: The Rekluse basket is cmpatible with the CreEXP aut-clutch, CreManual manual clutch, and the OEM clutch. INSIDE THIS DOCUMENT PREP & DISASSEMBLY BASKET ASSEMBLY CLUTCH INSTALLATION SETTING THE INSTALLED GAP CHECKING LEVER FREE PLAY GAIN TROUBLESHOOTING GUIDE BREAK-IN ENGINE IDLE SETTING CLUTCH NOISE & DRAG EXP TUNING OPTIONS & ENGAGEMENT SETTINGS MAINTENANCE BUMP STARTING INSTRUCTIONS CONVERSION TO A MANUAL CLUTCH 2016 Rekluse Mtr Sprts, Inc. 12000 W Franklin Rd. Bise, Idah 83709 208-426-0659 supprt@rekluse.cm
TOOLS NEEDED Metric scket set Metric end-wrench set Metric Allen keys/scket set Dental pick tls Trque wrench (in-lb & ft-lb, r N-m) Electric drill r drill press Mtrcycle transmissin il & grease Hammer and center-punch set INSTALLATION TIPS Watch the installatin vide by fllwing this QR cde r visiting rekluse.cm/supprt/vides. Read this entire dcument befre perfrming any steps, s yu will knw what t expect. Be sure t use prper eye prtectin, and wear rubber glves when handling ils and ther fluids. Laying the bike n its left side makes clutch wrk easier and eliminates the need t drain the il. An air r electric impact wrench wrks well t remve the center hub blt, r yu can place the bike in tp gear and hld the rear brake while lsening the center hub blt with a scket. Use clean, quality JASO-MA r JASO-MA2 certified transmissin il fr best perfrmance. REPLACEMENT GASKETS: It is recmmended t replace the gaskets fr the clutch cver and water pump cver whenever they are remved frm the bike. The shaft seals can be reused if they are in gd cnditin. The OEM part numbers fr the gaskets and seals are: Clutch Cver Gasket: Kawasaki part # 11061-0121 Water Pump Cver Gasket: Kawasaki part # 11061-0159 Water Pump Shaft Seals: Kawasaki part #s 92049-1359, 92049-1366 Kick-Start Shaft Seals: Kawasaki part # 92049-002 CLUTCH ASSEMBLY OVERVIEW Rekluse CreEXP KX 65 Page 2
INCLUDED PARTS Item # Item Type Qty 5 Pressure Plate 1 13 EXP Base * 2 24 Clutch Basket 1 27 Center Clutch Hub 1 47.1 Fastener M6 Lw-Head Screw 6 47.2 Fastener M6 x 25 Buttn Head Screw 6 51 Fastener - 1/4-Turn Pin * (extra included) 4 60 EXP Adjustment Spring * (extra included, see tuning ptins) 4 67 Steel Drive Plate 7 70.1 Basket Backing Plate 1 70.2 Spring Push-Plate 1 85 Wedge Assembly * 6 * Dentes parts assembled as cmpnents f the EXP disk assembly The picture abve is representative nly. See the parts list included with the prduct r visit Rekluse.cm/supprt fr a full parts fiche illustratin and part numbers. Rekluse CreEXP KX 65 Page 3
PREP & DISASSEMBLY 1. Place the Rekluse EXP disk in engine il t sak fr at least 5 minutes. 5. Turn ff the fuel valve, and lay the bike n its left side. Using a suitable catch pan, catch any fuel that might drain frm the carburetr tubes. 6. Remve the kick-start lever using a 10mm scket. 2. With the bike standing vertically n a center stand, place a suitable cntainer fr catching the engine clant under the water pump. 3. Use an 8mm scket t remve the clant drain blt frm the water pump cver, and then drain the engine clant int the cntainer. 7. Remve the brake pedal pivt blt using an 8mm Allen. Then, uncuple the spring frm the pedal and mve the pedal ut f the way. This will prvide access and clearance fr the clutch cver t be remved in the next steps. 4. Making sure that the engine/clant is nt ht, twist pen the radiatr cap t help evacuate all the clant frm the system int the cntainer. 8. Remve the 3x blts frm the water pump cver, and mve the cver aside. The clant-in hse can remain cupled t the water pump cver. Rekluse CreEXP KX 65 Page 4
9. Using an 8mm scket, remve the water pump impeller. 12. At the lever perch, remve all tensin frm the clutch cable by twisting the perch adjuster clckwise until it bttms ut. 10. Using a 6mm scket, lsen the hse clamp n the hse that ges frm the cylinder t the clutch cver (the clant-ut hse). Then remve the hse end frm the clutch cver. 13. At the threaded adjuster, use a 10mm endwrench t lsen the jam nuts remving tensin frm the clutch cable t the psitin f maximum cable/lever slack. 11. Bth the water pump husing and the clantut hse can be mved ut f the way f the clutch cver by gently tucking them between the engine and the exhaust pipe. NOTE: The clutch cable des nt have t be remved frm the clutch cver t enable access t the clutch. See the next steps fr the prcedure t tilt the cver ut f the way. 14. Using an 8mm scket, remve all f the clutch cver blts, and then lift the clutch cver free f the kick-start and water pump shafts. 15. Tilt the clutch cver up tward the gas tank (tp f the bike). Placing a large wrench between the frame and engine can help hld it ut f the way t access the clutch in the fllwing steps. Rekluse CreEXP KX 65 Page 5
16. Remve the OEM clutch parts named in the fllwing diagram. 18. Remve the thrust washer frm the bike, fllwed by the basket assembly. Ensure that the mainshaft cllar (which the basket spins arund) remains n the mainshaft in the engine. 17. Using a 14mm scket, remve the center hub blt. Then, lift the cre f the clutch ut by gripping the spring psts and pulling upward. NOTE: If the thrust washer is nt in the basket, it is likely stuck t the backside f the hub that was remved in the previus step. Rekluse CreEXP KX 65 Page 6
19. Set the OEM basket assembly n a wrkbench with the ring gear facing upward. Using a center punch and hammer, punch a divt int the center f each f the rivet heads. BASKET ASSEMBLY 23. Using the prvided Lctite n the screw threads, recmpile the basket assembly using the supplied Rekluse basket, backing plate, and screws. 20. Using the drill bit prvided, drill the heads ff f each rivet, s that the backing plate can be remved frm the assembly. Set yur drill t 300-400 RPM and use prper cutting fluid r il fr best results. 21. Carefully pry ff the backing plate and remve the ring gear and rubber dampers frm the basket. The OEM basket and backing plate will nt be reused. Trque the basket screws evenly t 80 in-lb (9 N-m) in a crisscrss pattern. 24. Using the hammer and center punch, stake the ends f the screws where they prtrude thrugh the inside f the clutch basket. Be sure t stake the screws DO NOT stake the aluminum basket. 22. Clean the rubber dampers and ring gear f all grit and rivet chips leftver frm drilling. WARNING: It is critical that yu apply Lctite and stake the ends f the screws r they can back ut. Rekluse is nt respnsible fr engine damage that may be caused by screws that back ut. Rekluse CreEXP KX 65 Page 7
CLUTCH INSTALLATION Crss-Sectin Overview: CreEXP 26. Install the Rekluse pressure plate [#5] in the rientatin shwn belw. It will fit lsely in the basket until the clutch plates and hub are installed in the fllwing steps. 25. Install the newly-cmpiled basket assembly int the bike ver the cllar n the mainshaft, fllwed by the OEM thrust washer. T get the ring gear teeth t prperly mesh with the crank and kick-starter gears, gently rtate the basket until it drps in and the teeth all mesh. DO NOT frce the basket in r damage may ccur. Rekluse CreEXP KX 65 Page 8
27. Install the Rekluse clutch pack as shwn, starting and ending with a steel drive plate [#67]. The EXP disk ges in 2 nd, after the first drive plate. 6x ttal drive plates will be used. 29. Install the OEM clutch springs, fllwed by the Rekluse spring push-plate [#70.2] and 6x buttn-head screws [#47.2]. Carefully tighten the screws each a little at a time in a star pattern t evenly lift the pressure plate befre trqueing the screws t 10 N-m (7.5 ft-lb) in a star pattern. One f yur OEM frictin disks will be left ver after this, replaced by the EXP disk. Refer again t the Crss-Sectin Overview at the beginning f this sectin fr clarificatin. NOTE: The last drive plate will be indexed t the pressure plate in nly the 6 prtruding tth features f the pressure plate. This is nrmal. 28. Install the Rekluse center clutch hub [#27]. DO NOT reuse the OEM screws, as interference with the clutch cver will ccur. NOTE: Shifting the transmissin int 5 th gear, and having a friend hld the rear wheel r rear brake pedal, will help t keep the clutch frm spinning t trque the screws and center hub blt. 30. Clean and dry any il r debris frm the threads f the OEM center hub blt, and apply the supplied Lctite t the threads n the blt. Then, install the blt int the mainshaft, and trque t 64 N-m (47 ft-lb) using a 14mm scket. T get the spline in the hub t line up with the mainshaft spline, gently rtate the hub back and frth while installing it until the splines mesh and the hub drps int place. DO NOT frce the hub int place r damage will ccur. Rekluse CreEXP KX 65 Page 9
31. Reinstall the OEM thrwut assembly int the spring push-plate. 34. Reinstall the kick-start lever. Trque t 12 N-m (9 ft-lb). 35. Clean and apply a little bit f grease t the O- ring seals n the rear brake pedal pivt blt, and then reinstall the brake pedal using the 8mm Allen scket. Trque t 25 N-m (18.5 ftlb). 32. Befre reinstalling the clutch cver: a) Replace the cver gasket with new. b) Check the cnditin f the rubber seals in the clutch cver, and replace if necessary. c) Lightly apply grease t the water pump shaft and kick-start shaft. NOTES: - Installing the clutch cver withut a new gasket culd cause engine il leaks. - Installing the clutch cver withut lightly greasing the water pump shaft and kickstart shaft culd cause seal damage. The OEM replacement gasket & seal part numbers are listed in the Installatin Tips sectin at the beginning f this dcument. 33. Reinstall the clutch cver using the OEM cver blts. Trque the cver blts evenly t 10 N-m (7.5 ft-lb). Rekluse CreEXP KX 65 Page 10
INSTALLED GAP SETTING DEFINITION: Installed Gap is the separatin in the clutch pack created by the adjustment f the clutch cable tensin. This gap is what allws the clutch t spin freely until the desired RPM is reached fr engagement; it must be set crrectly fr ptimal perfrmance, and rechecked befre each ride. Free Play Gain is the increase f lever free play as the aut-clutch engages. This happens when the RPM increase frm idle thrugh arund 10,000 RPM. Free Play Gain is caused by the expansin f the EXP disk which lifts the pressure plate away frm the thrwut assembly. 36. Using a 10mm wrench, tighten the clutch cable at the threaded adjuster t the pint where the clutch lever is tight against the perch. This is nt the final setting, but the starting pint fr adding mre cable tensin t find the crrect setting in the next steps. Optimal Free Play Gain yields 1/8 (3mm) f clutch lever mvement, measured at the end f the lever. This measurement at the lever crrelates t achieving the ideal installed gap. CHECKING LEVER FREE PLAY GAIN Lever Free Play is essentially the slack in the clutch cable system felt at the lever befre it starts actuating the clutch. Applying a light finger pressure will take up this slack. 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, which yu will perfrm befre every ride. Place the bike in neutral, start the engine and let it warm up fr 2-3 minutes. Rekluse CreEXP KX 65 Page 11
NOTICE Failure t check and verify Free Play Gain can cause failure r damage t this prduct. Setting the crrect gap is critical fr clutch perfrmance. Verify that the bike is in NEUTRAL befre checking Free Play Gain. Failure t d s may result in the bike lurching frward, and lss f cntrl and/r injury may result. Rubber Band Methd: It is recmmended that yu use this methd first t find yur Free Play Gain s yu can see what it is. Then, check it by hand as well s that yu can effectively and cmfrtably check free play gain every time yu ride. Wrap the included rubber band arund the uter end f the handlebar grip and attach it t the ball end f the clutch lever. A Rekluse aut-clutch can make yur mtrcycle appear t be in neutral when in gear, even when the engine is running and clutch lever released. Mtrcycles equipped with a Rekluse autclutch can mve suddenly and unexpectedly and cause riders t lse cntrl. T avid death, serius injury, and/r prperty damage, always sit n the mtrcycle t start it. NOTE: Befre perfrming this step, please visit ur website at rekluse.cm/supprt/vides t view the tech vide entitled: Hw t Check Free Play Gain Hand Methd: Free play gain shuld als be checked using yur hand, as yu will check it by hand befre every ride. With the bike at idle, apply enugh pressure t the lever t take up the initial freeplay (slack) shwn in the phts n the previus page. While cntinuing t apply light pressure, rev the engine t abut 10,000 RPM. The clutch lever shuld mve in 1/8 (3mm) under yur finger pressure as yu rev the engine and the aut-clutch engages. With the bike at idle in neutral, quickly blip (rev) the engine t abut 10,000 RPM and let it return t idle. The clutch lever shuld mve in abut 1/8 (3mm) tward the handlebar as yu rev the engine. NOTE: If yu are nt getting the crrect lever mvement, see the Free Play Gain Trubleshting sectin n the next page. Rekluse CreEXP KX 65 Page 12
FREE PLAY GAIN TROUBLESHOOTING Each adjustment shuld be dne in small increments ½-turn f the cable jam nut at a time. After each adjustment, repeat the rev-cycle until ptimal free play gain is achieved. Symptm: - Clutch lever mves in t far (t much free play gain) - Clutch has excessive drag - It is difficult t fully verride the clutch with the lever Answer: Installed Gap is t small Slutin: Adjust t add tensin t the clutch cable t increase the Installed Gap inside the clutch pack. Symptm: - Clutch lever des nt mve enugh r des nt mve at all (t little free play gain) - Clutch is slipping Answer: Installed Gap is t large Slutin: Adjust t remve tensin frm the clutch cable t reduce the Installed Gap inside the clutch pack. BREAK IN Fllw these prcedures fr a new installatin and any time new frictin disks r EXP bases r wedges are installed. 1. Rev cycles: Warm up the bike fr 4-5 minutes. With the bike in neutral and yur hand ff f the clutch lever, rev the engine 10 times, being sure t let it return t idle between each rev cycle. 2. 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 a slight amunt f frward creep. 3. Nw that the bike is idling in first gear, slwly apply thrttle t begin mving. T break in the clutch cmpnents, perfrm the fllwing rll-n starts in 1st and 2nd gear withut using the clutch lever: In 1st gear, accelerate mderately t apprximately 10,000 RPMs and cme t a stp repeat this 5 times. Next, starting in 2nd gear, accelerate mderately t apprximately 10,000 RPMs then cme t a stp repeat this 5 times. 4. Nw that the EXP is brken-in and the clutch is warm, re-check free play gain at yur clutch lever and adjust if necessary. Yur clutch pack will expand slightly with temperature, s final adjustments shuld be made when the bike is warm. Nw yu are ready t ride! DO NOT RIDE WITHOUT SUFFICIENT FREE PLAY GAIN! Checking free play gain is easy and takes less than a minute t perfrm. Fr ptimum perfrmance and lngevity, check free play gain when the bike is warm at the start f every ride. Rekluse CreEXP KX 65 Page 13
ENGINE IDLE SETTING Turning the idle screw can be dne by hand. Turn this screw t adjust the engine idle t the pint where the engine des nt stall either in neutral r in gear with the bike at a standstill, but the clutch des nt start t engage. If in a track-side pinch, it is easier t change idle settings rather than EXP spring settings. See EXP TUNING OPTIONS sectin fr mre inf. CLUTCH NOISE & DRAG 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 r JASO-MA2 rated il fr best clutch perfrmance. Dirty r ld il can tend t prduce mre clutch nise. Sme heavy-duty il stabilizers r ther additives have been knwn t reduce nise and make shifting smther, but be sure that any additives yu might emply are apprved fr use in wet-clutch mtrcycles. - Installed Gap: Adjusting the Installed Gap WILL NOT affect clutch squeal r chatter! - Drag: Because the centrifugally-actuated prtin f this clutch is sensitive t RPM, the clutch may drag mre than stck and pssibly may drag mre nticeably when cld. If this ccurs, warm the bike up by allwing it t idle fr several minutes befre riding. If drag persists and yur installed gap is crrect, inspect yur clutch plates fr signs f wear r heat damage. - EXP Spring Setting: If yur il is warm and the clutch plate cnfiguratin is in spec, yet yur bike wants t drag, pulse, r chatter during idle r takeff, it may be necessary t tune the EXP springs fr a higher-rpm clutch engagement. See the EXP TUNING OPTIONS sectin n the fllwing pages fr instructins. Rekluse CreEXP KX 65 Page 14
EXP TUNING OPTIONS Included are spring ptins t tune the engagement RPM f the EXP disk. The EXP disk cmes set with the recmmended Medium setting frm Rekluse. See the fllwing chart fr setting ptins. Kawasaki KX 65, Suzuki RM 65 ENGAGEMENT SETTING Lw Medium (the EXP is pre-assembled with this setting) High SPRING CONFIGURATION 4 Red Springs 2 Red & 2 Blue Springs 4 Blue Springs Adjusting the engine idle speed t match yur engagement setting is imprtant and greatly affects the verall feel f hw the EXP disk engages and disengages. T prevent freewheeling and maximize engine braking, set the idle just belw the pint where the clutch stars t drag while the bike is idling in gear and warmed up. The idle shuld be high enugh s that the engine desn t stall when the bike is in gear with the thrttle clsed, but nt s high as t mve the bike frward. With a small pening f the thrttle, the bike shuld mve frward. It is NOT necessary t disassemble the EXP halves t change springs! T change springs, remve 2 f the ¼-turn pins frm ne side f the EXP, replace springs, and re-install ¼-turn pins. Next, flip the EXP disk ver and repeat n the ther side if necessary. T maintain even pressure when using tw different clr spring sets, install ne clr set f 2 n ne side f the EXP and the remaining clr set f 2 n the ther side. CAUTION: If yu disassemble the EXP disk, then the plymer bearing pads may fall ut f the wedges r be stuck t the ramp surfaces f the EXP bases. Take care t ensure that all pads are crrectly placed int wedge pckets using gentle pressure t avid damage t the pad surfaces befre reassembling the EXP. Prperly seated pads will be secured in place nce the EXP is reassembled. Operating the clutch withut pads in place will cause part damage r failure. Replacement pad kits are available separately frm Rekluse. Rekluse CreEXP KX 65 Page 15
MAINTENANCE - Maintain adequate free play gain, checking befre every ride and adjusting if necessary. - Keep up with regular il changes as per the bike manufacturer s recmmendatins. Clutch functin and lngevity depends n il quality. - Peridically clean and lubricate the clutch cable t maintain best functinality. - Inspect all f yur clutch parts every 20 hurs f peratin fr signs f wear r excessive heat, and replace cmpnents as necessary. - If yu find yurself making frequent slave cylinder adjustments t fix free play gain, drag, r perfrmance, it is likely time t replace wrn clutch disks. Measure yur frictin disks and replace as necessary. Frictin disk minimum allwable thickness = 0.115 (2.9mm) EXP disk minimum allwable thickness = 0.416 (10.6mm) - Excessive heat r clutch slip can cause premature clutch failure. Once extreme temperatures are reached, irreversible damage will ccur. Insect yur clutch plates; if the frictin disks lk burnt r glazed, r the drive plates are blue/black in clr r warped, it is best t replace the entire clutch pack. - Repeat the break-in prcedure anytime the frictin disks r EXP bases r wedges are replaced. Always sak new frictin disks r EXP bases in il fr at least 5 minutes befre installing. BUMP-STARTING INSTRUCTIONS If yur bike needs t be bump-started due t a dead battery r any ther reasn, fllw the steps belw t quickly bump-start yur bike. 1. Lsen the clutch cable tensin until there is slack in the cable (the pint at which the cable is n lnger prelading the pressure plate inside the clutch). 2. Bump start the bike. The clutch will functin like a manual clutch at this pint. 3. Once the bike is started, readjust the cable tensin as per the previus instructins t reset the installed gap by achieving prper free play gain at the lever. Visit Rekluse.cm fr mre detailed instructins, vides, parts-fiche dcuments, and warrantee infrmatin. Rekluse CreEXP KX 65 Page 16
CONVERTING TO A REKLUSE MANUAL CLUTCH (OPTIONAL) NOTE: When the installatin f the CreEXP aut-clutch is perfrmed, the bike s basket assembly is disassembled and then reassembled using the Rekluse basket instead f the stck basket. The Rekluse basket is taller than the stck basket, which is required fr Rekluse clutches t fit and functin. This Rekluse basket is fully cmpatible with the stck clutch cmpnents, and can be used as a direct OEM basket replacement if desired. If desired, the CreEXP clutch can be cnverted t a CreManual clutch by purchasing a few additinal Rekluse clutch plates and recnfiguring the clutch pack as shwn belw. The cre cmpnents (center hub [#27], pressure plate [#5], springs, etc.) will all remain assembled in the same way as with the CreEXP clutch. The Rekluse CreManual clutch cntains 7x frictin disks versus the stck clutch s 5x disks. The additinal 2x frictin disks in the Rekluse CreManual clutch ffers 40% mre trque capacity than the stck clutch, and can prvide reduced clutch temperatures and increased durability in additin t the perfrmance advantages. Cnverting t CreManual Clutch Parts Required: Item # Item Type Qty. Mre Than CreEXP Qty. Ttal 67 Steel Drive Plate 2 8 69 Frictin Disk (can be purchased frm Kawasaki r Rekluse) 3 7 Rekluse CreEXP KX 65 Page 17
Crss-Sectin Overview: CreManual 1. T cnvert the CreEXP clutch t a CreManual clutch, yu will first need t purchase an additinal 2 steel drive plates [#67] and 3 frictin disks [#69] frm Rekluse (alternatively, the additinal frictin disks can be purchased frm Kawasaki, since they are the same as the OEM disks). 2. Remve the clutch cmpnents frm the bike dwn t the pressure plate [#27], including the clutch pack. 3. Recnfigure the clutch pack t include 8x ttal drive plates [#67] and 7x ttal frictin disks [#69], then reinstall the pressure plate, center hub, and the rest f the cmpnents up t the slave cylinder. 4. Set the cable tensin t OEM spec (8 t13mm f clutch lever freeplay). Rekluse CreEXP KX 65 Page 18