Rekluse EXP - User Manual

Doc ID: 193-300A
Revision: 121718
1
©2018 Rekluse Motor Sports
Rekluse Motor Sports, Inc.
customerservice@rekluse.com
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

Summary

EXP Assembly Inspection

Symptoms of Wear

Symptoms of EXP assembly wear include clutch slippage, stalling, or dragging with correct free play.

Inspection Schedule

Defines 'Light' and 'Heavy' inspection ranges based on rider use and terrain conditions.

EXP Assembly Inspection Procedure

Step 1: Remove and Clean EXP Assembly

Remove the EXP assembly from the bike and clean off any debris or oil.

Step 2: Measure EXP Thickness

Measure EXP width from friction pad to friction pad and check against minimum thickness requirements.

Step 3: Test Wedge Functionality

Push and release wedges to ensure they move easily and spring back without catching.

Step 4: Visual Inspection of EXP

Inspect EXP for tab hammering, damage, missing friction pads, and glazing.

Step 5: Disassemble EXP Assembly

Push and turn pins to unlock and remove pins and springs for disassembly.

Step 6: Inspect Ramps

Inspect EXP ramps for raised outlines (burrs) or indentations; replace if damaged.

Step 7: Inspect Teflon Pads

Inspect Teflon pads in wedges for proper seating and signs of damage like nicks or cuts.

Step 8: Reassemble EXP Bases

Reassemble EXP bases, wedges, springs, and pins, ensuring wedges move freely.

Overview

1. Function Description
2. Usage Features
3. Maintenance Features

The Rekluse EXP assembly is a crucial component in a clutch system, designed to manage power transfer and engagement. It is built with high-quality materials, but like all clutch components, it is subject to natural wear and tear, which varies based on rider usage and terrain. The primary function of the EXP assembly is to allow for automatic clutch engagement and disengagement, providing a smoother riding experience and preventing engine stalls.

Function Description

The EXP assembly operates by utilizing internal ramps and wedges that respond to engine RPMs. As engine speed increases, the wedges move outward due to centrifugal force, engaging the clutch and transferring power to the drivetrain. Conversely, when engine speed decreases, the wedges retract, disengaging the clutch and allowing the engine to idle without stalling. This automatic functionality eliminates the need for manual clutch lever operation in many riding situations, enhancing control and reducing rider fatigue. The system is designed to provide consistent performance, but its effectiveness relies on proper maintenance and timely inspection of its components.

Usage Features

The Rekluse EXP assembly offers several usage features that enhance the riding experience:

• Automatic Clutch Engagement/Disengagement: The most significant feature is the automatic operation of the clutch, which allows riders to focus more on throttle control and braking, especially in technical terrain or stop-and-go situations. This can lead to improved traction and reduced rider fatigue.
• Stall Prevention: By automatically disengaging the clutch at low RPMs, the EXP assembly prevents the engine from stalling, which is particularly beneficial for off-road riding or in situations where quick stops are common.
• Adjustable Free Play Gain: The system allows for adjustment of the "Free Play Gain," which influences how the clutch engages and disengages. Proper adjustment is critical for optimal performance and to prevent symptoms like slipping, stalling, or excessive dragging.
• Versatility Across Riding Conditions: The EXP assembly is designed to perform across various riding conditions, from dirt/off-road to street and adventure/dual sport, with recommended inspection intervals tailored to the intensity of use.

Maintenance Features

Regular inspection and maintenance are vital to ensure the longevity and optimal performance of the Rekluse EXP assembly. The manual outlines a comprehensive inspection schedule and detailed steps for maintenance:

• Inspection Schedule: The assembly should be inspected at regular intervals, with "Light" inspection ranges for moderate use and "Heavy" ranges for extreme environments. These intervals are specified in hours for dirt/off-road and in miles for adventure/dual sport and street use.
• Symptoms of Wear: Riders should be aware of symptoms indicating wear, such as the clutch slipping or stalling even with correct Free Play Gain adjustment, excessive clutch dragging, or difficulty in finding the proper Free Play Gain adjustment.
• Step-by-Step Inspection Process:
  • Removal and Cleaning: The first step involves removing the EXP assembly from the bike and thoroughly cleaning it to remove debris and oil.
  • Measuring Thickness: The width of the EXP assembly from friction pad to friction pad must be measured. Minimum thickness specifications vary by part number, and if the assembly is below the minimum, the EXP bases and Teflon pads require replacement.
  • Testing Wedges: The wedges within the assembly need to be tested for free movement and spring-back. Wedges should move easily and return to their original position without catching. Sticking wedges indicate a need for further inspection and potential replacement of EXP bases and Teflon pads.
  • Visual Inspection for Hammering: The EXP assembly tabs should be inspected for "hammering," which occurs when one tab is compressed and narrower than the other. If the wear exceeds a specified tolerance (.020" or .5 mm), the assembly must be replaced. For KTM/Husqvarna DDS models, minor hammering allows for flipping the assembly to extend its life, but also necessitates inspection of the inner hub and dampers. For traditional clutch models, clutch basket dampers should be inspected if hammering is present.
  • Visual Inspection for Damage and Missing Pads: The EXP assembly should be checked for any signs of damage on the tabs. All friction pads on both sides must be securely bonded to the bases; missing pads necessitate replacement of the EXP bases.
  • Checking for Glazing: Friction pads should be inspected for glazing, which appears as a shiny, glass-like finish, even after cleaning off oil. Glazed pads indicate a need for EXP base replacement. Normal pads will have a rough finish despite appearing black from oil.
  • Inspecting for Discoloration: The assembly should be checked for signs of discoloration. Light staining is often oil-related and may not affect function, but heavy staining can indicate high heat and may require replacement of bases and wedges.
  • Disassembly: The manual provides instructions for disassembling the EXP assembly by removing the quarter turn pins and springs, then separating the bases and wedges.
  • Inspecting Ramps: All ramps inside both EXP bases must be inspected for raised outlines (burrs) or indentations. Any such damage requires replacement of the EXP bases and Teflon pads. Normal ramps may have machine marks or appear shiny/polished.
  • Inspecting Wedges and Teflon Pads: The Teflon pads in the wedges should stick slightly above the edge of the wedge pocket. If they sit flush or below, they need replacement. Pads should be smooth, free of nicks, cuts, or embedded debris. Damaged or worn pads require replacement, with kits available from Rekluse.
• Reassembly and Break-in: After inspection and replacement of worn components, the EXP bases are reassembled, ensuring wedges and Teflon pads are correctly placed. Springs and quarter turn pins are reinstalled. A break-in procedure, detailed in the installation manual or on the Rekluse website, is required for new components.
• Post-Maintenance Adjustment: After reassembly and break-in, the Free Play Gain must be re-checked before riding to ensure optimal performance.

This comprehensive approach to maintenance ensures that the Rekluse EXP assembly continues to provide reliable and efficient clutch operation, extending its lifespan and enhancing the overall riding experience.

Rekluse EXP Specifications

General

Type	Auto Clutch
Material	Steel
Compatibility	Specific motorcycle models
Installation	Requires mechanical skill and tools.
Engagement	Automatic
Adjustability	Adjustable engagement