Rekluse EXP Guida rapida
©2014 RekluseMotorSports
RekluseMotorSports, Inc.
12000W FranklinRd
Boise,Idaho83709
208-426-0659
support@rekluse.com
REKLUSE MOTOR SPORTS
EXPKit forHarley-DavidsonBigTwin
USER’S GUIDE
Doc ID: 193-6201A
Doc Rev: 062714
OVERVIEW
This kit replaces the OEM clutch pack (friction disks and drive plates) to achieve the necessary
performance and function.
No modification of OEM parts is necessary.
Replacement of the OEM primary chaincase cover gasket is recommended with this install.
INSIDE THIS DOCUMENT
oCHECKING “FREE PLAY GAIN”
oBREAK-IN
oTROUBLESHOOTING GUIDE
oMAINTENANCE
oEXP TUNING OPTIONS & ENGAGEMENT SETTINGS
RESOURCES
Online parts fiche:
Installation video:
Rekluse EXP for Harley-Davidson Big-Twin –Cable-Actuated Page 2
CLUTCH ASSEMBLY OVERVIEW
CUTAWAY VIEW
Basket Sleeves: used to protect the basket from the thin cross-section of the Rekluse friction disks and
will extend the durability and life of your clutch.
Clutch Pack: consists of 12 total friction disks (11 thin disks plus the EXP disk). The TorqDrive friction
disks are thinner than OEM which allows for more plates in the same space, yielding optimized clutch
hookup and modulation.
OEM Throwout Adjuster: utilizes the OEM adjuster components to set the “Installed Gap” (for cable-
actuated models).
OEM Belleville Spring: reuse the spring that was installed in your bike, or choose from an array of
spring options available from Harley-Davidson (see chart).
Rekluse EXP for Harley-Davidson Big-Twin –Cable-Actuated Page 3
CHECKING LEVER
FREE PLAY GAIN
NOTE: Before performing this step,
please visit our website at
rekluse.com/support to view the
TECH VIDEO entitled:
“How to Check Free Play Gain”
“Free Play Gain” is the increase of lever free play
as the auto-clutch engages. This happens when
the RPM increase from idle through around 2500
RPM. Free Play Gain is caused by the expansion of
the EXP disk which lifts the pressure plate and
removes tension from the clutch cable.
Optimal Free Play Gain yields 1/8” (3mm) of clutch
lever movement, measured at the end of the lever.
This measurement at the lever correlates to
achieving the ideal installed gap.
The following steps explain two ways to check Free
Play Gain. One will use the rubber band that has
been included in the clutch kit and one explains
using your hand, which you will perform before
every ride.
WARNING
An auto-clutch can make your motorcycle
appear to be in neutral when in gear, even
when the engine is running and clutch lever
released.
Motorcycles equipped with an auto-clutch
can move suddenly and unexpectedly and
cause riders to lose control.
To avoid death, serious injury, and/or
property damage:
Always sit on the motorcycle to start it
Verify that the motorcycle is in neutral
by applying both the front and rear
brake while applying just enough throttle
that the bike would start to move
forward if it were in gear.
Place the bike in neutral, start the engine and let it
warm up for 2-3 minutes to idle down.
Rubber Band Method:
It is recommended that you use this method first
to find your Free Play Gain so you can see what
it is. Then, check it by hand as well so that you
can effectively and comfortably check free play
gain every time you ride.
Wrap the included rubber band around the outer
end of the handlebar grip and loop it through
itself, attaching it to the ball end of the clutch
lever.
Rekluse EXP for Harley-Davidson Big-Twin –Cable-Actuated Page 4
With the bike at idle in neutral, quickly blip (rev)
the engine to at least 3500 RPM and let it return
to idle. The clutch lever should move in
about 1/8” (3mm) toward the handlebar as
you rev the engine.
Note: If you are not getting the correct lever
movement, see the “Free Play Gain
Troubleshooting Guide” on the next page.
Hand Method:
Free play gain should also be checked using
your hand, as you will check it by hand before
every ride. With the bike at idle, apply enough
pressure to the lever to take up the initial
freeplay (slack) shown in the photos on the
previous page. While continuing to apply light
pressure, rev the engine to at least 3500 RPM.
The clutch lever should move in 1/8” (3mm)
under your finger pressure as you rev the
engine and the auto-clutch engages.
BREAK –IN
1. Rev cycles: Warm up the bike for 2-3 minutes.
With the bike in neutral and your hand off of the
clutch lever, rev the engine 10 times, being sure
to let it return to idle between each rev cycle.
2. With the engine running, pull in the clutch lever
and click the bike into gear. Slowly release the
clutch lever. The bike should stay in place,
perhaps with a slight amount of forward creep.
3. Now that the bike is idling in first gear, slowly
apply throttle to begin moving. To break in the
clutch components, perform the following roll-on
starts without using the clutch lever, in 1st and
2nd gear: In 1st gear, accelerate moderately to
approximately 3500 RPM and come to a stop—
repeat this 10 times. Next, starting in 2nd gear,
accelerate moderately to approximately 3500
RPM then come to a stop—repeat this 10
times.
4. Re-check free play gain at your clutch lever and
adjust if necessary at this point. Your clutch
pack will expand slightly as it gets hot during
normal riding, so it is a good idea to check your
freeplay gain after your bike is warmed up
before each ride.
NOTICE
Failure to check and verify Free Play Gain
can cause failure or damage to this product.
FREE PLAY GAIN
TROUBLESHOOTING
Each adjustment can be performed just by
removing the derby cover, and should be done in
small increments. After each adjustment, repeat
the rev-test until optimal free play gain is achieved.
Symptom:
- Clutch lever moves in too far (too much free
play gain)
- Clutch has excessive drag
- It is difficult to fully override the clutch with
the lever
Reason: Installed Gap is too small
Solution: Turn the Adjuster Screw inwardly
(clockwise) to increase the Installed Gap.
Symptom:
- Clutch lever does not move enough or does
not move at all (too little free play gain)
- Clutch is slipping
Reason: Installed Gap is too large
Solution: Turn the Adjuster Screw outwardly
(counter-clockwise) to reduce the Installed Gap. It
may be helpful to re-find the starting point.
Rekluse EXP for Harley-Davidson Big-Twin –Cable-Actuated Page 5
MAINTENANCE
- Maintain adequate free play gain, checking
before every ride and adjusting when
necessary.
- To prolong the life of the clutch, inspect your
clutch parts at the interval prescribed by your
owner’s manual for signs of wear or excessive
heat, and replace components as necessary.
ABOUT FREE-WHEELING
If the clutch lever is pulled while the motorcycle is moving and held in long enough for the engine RPMs to drop
all the way to idle, the Rekluse auto-clutch clutch will automatically disengage the clutch and it will not re-
engage the clutch until the RPMs rise above idle. If a small amount of throttle is not applied as the clutch lever
is released, the clutch will remain disengaged and the motorcycle will be "free-wheeling"; coasting down the
road with the clutch disengaged and the engine at idle.
Free-wheeling can be hazardous, especially when downshifting. When your motorcycle is free-wheeling after
a downshift, when throttle is applied, the clutch will engage very suddenly. Sudden engagement of the clutch
from a free-wheeling state may cause the rear tire to slow suddenly from the engine's compression braking
effect, possibly causing the rear tire to skid creating a loss of control.
WARNING
An auto-clutch can engage suddenly and cause death, serious injury, and/or property damage.
Loss of control can result from sudden and unexpected engagement of the clutch from a free-
wheeling state. Rear tire may slow from the engine's compression braking effect and cause
the rear tire to skid.
To avoid free-wheeling and/or the risk of sudden unexpected engine compression braking you must
always select a suitable transmission gear in consideration of your ground speed, engine RPM and
terrain. When releasing the clutch lever after downshifting, it is important to let the clutch lever out
slowly and always apply a small amount of throttle as the clutch lever is released to control engine
compression braking.
Downhill riding with higher auto-clutch engagement speeds requires adjustments to your riding style.
For example, coming over the top of a hill in first gear and slowing to the point that the Rekluse auto-
clutch disengages the clutch, your motorcycle will now be “free-wheeling” down the hill. With higher
auto clutch engagement speeds, engine speed engages the Rekluse auto-clutch, not wheel speed. It
may be possible to reach very high speeds coming down a hill in a very low gear. When throttle is
applied, the Rekluse auto-clutch will engage suddenly. In this situation, severe compression braking
could cause an accident or engine damage.
!
Rekluse EXP for Harley-Davidson Big-Twin –Cable-Actuated Page 6
EXP TUNING OPTIONS
Included are spring options to tune the engagement RPM of the EXP friction disk. The EXP friction disk comes
set with the recommended “Medium” setting from Rekluse. See the following chart for settings.
ENGAGEMENT SETTING
SPRING CONFIGURATION
1998 - 2006
2007+
Low
3 Blue & 3 Gold
6 Gold
Medium
6 Gold
3 Gold & 3 Green
High
3 Gold & 3 Green
6 Green
Adjusting the engine idle speed to match your engagement setting is important and greatly affects the overall
feel of how the EXP disk engages. To prevent freewheeling and maximize engine braking, set the idle so there
is a slight amount of drag while the bike is idling in gear and warmed up. The idle should not be so high as to
move the bike forward in gear with the throttle closed. However, with a small opening of the throttle the bike
should move forward.
It is NOT necessary to disassemble the EXP halves to change springs! To change springs, remove 3 of the
¼-turn pins from one side of the EXP, replace springs, and re-install ¼-turn pins. Next, flip the EXP disk over
and repeat on the other side if necessary. To maintain even pressure when using two different color spring
sets, install one color set of 3 on one side of the EXP and the remaining color set of 3 on the other side.
NOTICE
Bearing pads may fall out or be stuck to the ramp surfaces of the EXP bases as you disassemble
the EXP. Operating the clutch without the pads in place will cause part damage or failure.
Ensure all pads are correctly placed into wedge pockets using gentle pressure to avoid damage to the pad
surfaces before reassembling the EXP. Properly seated pads will be secured in place once the EXP is
reassembled.
Altri manuali per EXP
2
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