Rekluse EXP Installation instructions

Doc ID: 193-300A

Revision: 121718

Rekluse Motor Sports, Inc.

[email protected]

The Rekluse EXP assembly is built using high quality

materials, however, it does experience natural wear and tear

like any clutch component. The amount of wear is based on

the rider’s use and type of terrain.

It is important to inspect the EXP assembly at regular

intervals for signs of wear, including the internal ramps and

wedges.

Symptoms of wear may include:

•The clutch either slips or stalls even with Free Play

Gain adjusted correctly

•The clutch excessively drags

•It is difficult to find the proper Free Play Gain

adjustment

INSPECTION SCHEDULE

The EXP assembly should be inspected using the following

schedule. The “Light” inspection range is based on an

average rider’s moderate use.

The “Heavy” inspection range is based on riding in extreme

environments or riding conditions.

Bike Model

Clutch Use

Light Heavy

Dirt / Off-Road 40-50 hours 20-30 hours

Adventure / Dual

Sport

8,000-15,000 miles 3,000-5,000 miles

Street 10,000-20,000 miles 5,000-8,000 miles

EXP ASSEMBLY INSPECTION

Doc ID: 193-300A

Revision: 121718

INSPECT EXP ASSEMBLY

Use the following instructions to properly inspect the EXP

bases, wedges, and Teflon pads.

Step 1: Remove the EXP assembly

a.Remove the EXP assembly from the bike. Instructions

for disassembling the clutch can be found in your

installation manual.

b.Clean off any debris or oil from the EXP bases with a

clean towel.

Step 2: Measure the EXP

a.Measure the width of the EXP assembly from friction pad

to friction pad. Use the part number stamped on the EXP

base tab to determine which measurement is correct for

your bike model.

•For EXP part number 140-216: minimum thickness

is .590” (14.99 mm).

•For all other part numbers: minimum thickness is

.416” (10.57 mm).

b.If the EXP is above the minimum thickness, continue

with the next step. If the EXP is below the minimum

thickness, replace the EXP bases and Teflon pads.

Measure from friction pad

to friction pad.

Doc ID: 193-300A

Revision: 121718

Step 3: Test the wedges

a.Push a pair of wedges (opposite from each other) from

the inside of the EXP assembly toward the outside of the

assembly.

b.Release the wedges once they have reached the outside

edge of the assembly. The wedges should move easily

and spring back in place without catching once released.

•If all the wedges in the EXP assembly spring back,

continue with the next step.

•If one or more of the wedges stick, the EXP bases and

Teflon pads may need to be replaced. Continue with

the next step for further inspection.

Push and release

wedge pairs

Doc ID: 193-300A

Revision: 121718

Step 4: Visually inspect EXP

•Inspect the EXP assembly for any evidence of

hammering on the tabs. A hammered tab is when one of

the EXP base tabs has been compressed and is

narrower than the other tab. If the EXP tab wear is more

than .020” (.5 mm), the EXP assembly needs to be

replaced.

oKTM / Husqvarna DDS models:

If the hammering is less than .020” (.5 mm), the

EXP assembly can be flipped over to extend the

life of the EXP. If any amount of hammering is

present, inspect the inner hub and dampers for

signs of wear in addition to inspecting the EXP

assembly. Replace the dampers in the hub

assembly if there is rotational play as well as the

EXP assembly.

oFor traditional clutch models:

If hammering is present, inspect the clutch basket

dampers in addition to inspecting the EXP

assembly.

c.Inspect the EXP for signs of damage.

Hammered

tab

Doc ID: 193-300A

Revision: 121718

•A damaged tab is when the EXP tab(s) have visible

signs of damage. If there are any signs of damage,

replace the EXP bases.

d.Check that all the friction pads on both sides of the EXP

assembly are still bonded onto the bases. If any of them

are missing, replace the EXP bases.

e.Check the friction pads for glazing. Due to the dark color

of the friction pad material, the pads will appear almost

black as soon as they are put in oil.

•A normal friction pad will still have a rough finish

even though the pads are black.

Missing

friction pad

Normal friction pad

Doc ID: 193-300A

Revision: 121718

•In contrast, glazing will appear shiny and feel like

glass, even after oil is cleaned from the friction pads.

If the friction pads are glazed, replace the EXP

bases.

f. Inspect both sides of the EXP assembly for signs of

discoloration.

•Light staining may be caused by the oil and the EXP

may still function properly.

Light staining

Glazed friction pad

Doc ID: 193-300A

Revision: 121718

•Heavy staining may indicate high heat from the clutch,

and the bases and wedges may need to be replaced.

g.Once the visual inspection is complete, continue with the

next step.

Step 5: Disassemble the EXP assembly

a.Using a flat-blade screwdriver, push the ¼ turn pin in far

enough to clear the opposite side of the EXP to unlock

the pin.

b.With the pin still pushed past the base, turn ¼ of a turn

to remove the pin and spring. Remove all the remaining

pins and springs the same way.

Heavy staining

Doc ID: 193-300A

Revision: 121718

c. Separate the bases and remove the wedges. Be aware

that Teflon pads may stick to base ramps from oil tension.

Just remove the stuck pads from the EXP base and set

them aside before continuing to inspect the bases.

Step 6: Inspect the ramps

a.Inspect all the ramps that are located inside of both EXP

bases. Replace the EXP bases and Teflon pads if there

is any evidence of a raised outline on the ramp, or if the

ramp has an indentation. See the following examples.

EXP ramps

for inspection

Doc ID: 193-300A

Revision: 121718

Normal - Ramps with machine marks or look

shiny/polished are normal. These can be reused.

Machine marks

Shiny or polished

Damaged - Ramps that have a raised outline (burr)

or have an indentation are damaged and need to be

replaced.

Raised mark (burr) Indentation

NOTE: If you replace the EXP bases, it is HIGHLY

RECOMMENDED that you replace the Teflon pads or

wedges as well for best performance.

Doc ID: 193-300A

Revision: 121718

Step 7: Inspect the wedges

a.Inspect all the Teflon pads in the wedges. The pads

should stick slightly above the edge of the wedge pocket.

If the pads sit flush or below the edge of the pocket,

replace the pads.

NOTE: If a Teflon pad has

fallen out during

disassembly, press the pad

back into the wedge pocket

using the flat side of a

screwdriver.

Do not press directly in the center of the pad with the tip

of the screwdriver or with any sharp object. This will

make an indent in the pad and the wedge will not

function properly.

b.Inspect the pads for damage. The pads should be smooth

with no nicks, cuts, or imbedded debris.

•If the Teflon pads are good, continue with the next

step.

•If the Teflon pads are worn or damaged, the Teflon

pads need to be replaced. A kit is available through

Rekluse.

Pads should

be slightly

above the

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