Rekluse Core EXP Install Question

[TavisB]

Edit: Had a question about the friction plates, but figured it out.

New issue:

My kit didn't come with the set screws . Has this happened to anyone else?

 

[thumperrider1]

my set screws were installed already when i pulled it out of the box. I'm sure if you call REkluse they will have them out to you in a day.

 

[andoman]

Ditto. They will overnight them to you. Rekluse has some of the best customer service on earth.

Also, DON'T FORGET TO TIGHTEN THEM DOWN!!!
If the clutch drag increases noticeable shortly after you were in there, stop and look to see that things are tight.

One other thing: I couldn't get the gap right with the recommended setup. Always too much clutch drag regardless of how many "ticks" past one turn I went. Installed the light springs (blue ones, as I recall) on both sides and it resulted in perfect engagement.

 

[GasTimppa]

I agree rekluses great customer service. I e-mailed and called one day and had new part in my hand within 24 hours. And I live in northern europe

 

[TavisB]

Called Rekluse, parts are on the way .

 

[TavisB]

Fun fun...I got the set screws in no problem. Now I am having an issue with the Rekluse clutch cover. My stock cover is 0.450" where the bolts go through. The Rekluse cover is only 0.360" thick which causes my bolts to bottom out in the case . I've been on the phone with an engineer from Rekluse and they are trying to figure out what is going on.

 

[TavisB]

So my solution is grind down my bolts, get shorter bolts, or use a thicker gasket.

Have a gasket on the way, but I need to get the bike going so I'll be searching for shorter bolts today.

 

[shultzy]

You could just use washers on the bolts or cut down the existing bolts a little.
Using the washers as spacers would work fine and is reversable.

 

[TavisB]

You could just use washers on the bolts or cut down the existing bolts a little.
Using the washers as spacers would work fine and is reversable.

Yep. I forgot to list that as an option they gave me. I didn't have any washers small enough on hand to do it, but I'm heading to the hardware store now. I'm sure I'll find something that will work.

I don't want to grind down the original bolts, I'm afraid I'll damage the bolt threads and in turn the threads in the case.

 

[TavisB]

Ditto. They will overnight them to you. Rekluse has some of the best customer service on earth.

Also, DON'T FORGET TO TIGHTEN THEM DOWN!!!
If the clutch drag increases noticeable shortly after you were in there, stop and look to see that things are tight.

One other thing: I couldn't get the gap right with the recommended setup. Always too much clutch drag regardless of how many "ticks" past one turn I went. Installed the light springs (blue ones, as I recall) on both sides and it resulted in perfect engagement.

I found some shorter bolts today and got the cover on. I tried to do the break in procedure but found that the clutch was really grabby. At first I could not get it to idle in gear, and even when the clutch lever was fully in the clutch was still grabby. After I rode it around a bit it has improved. I may try changing out the springs next to get it perfect.

 

[andoman]

I found some shorter bolts today and got the cover on. I tried to do the break in procedure but found that the clutch was really grabby. At first I could not get it to idle in gear, and even when the clutch lever was fully in the clutch was still grabby. After I rode it around a bit it has improved. I may try changing out the springs next to get it perfect.

EXACTLY the symptoms I had. I knew I would have to change springs when I couldn't even get it to completely disengage with the lever in. With the spring change and 1 turn + 2 ticks it was perfect.
Don't know what to say about your screws. My lengths were just fine.

 

[desertgasser300]

EXACTLY the symptoms I had. I knew I would have to change springs when I couldn't even get it to completely disengage with the lever in. With the spring change and 1 turn + 2 ticks it was perfect.
Don't know what to say about your screws. My lengths were just fine.

I also had the same symptoms. Changed the EXP springs to all blue, 1 full turn + 2 ticks. Clutch now works like stock and will idle all day in gear.

This is why some of us have been having bolt length issues. I had the same thing happen, I just used a couple of small washers to make up the depth issue. The stock cover bolt holes are taller compared to the rekluse cover. I'm guessing that some have issues and some do not because of different years and different length bolts being used. May be a consistency thing at the factory?