INSTALLATION GUIDE. Doc ID: Doc Rev:

Transcription

1 REKLUSE MOTOR SPORTS The Rekluse Clutch Basket Kit INSTALLATION GUIDE Doc ID: Doc Rev: TOOLS NEEDED Center Punch & Hammer Drill Press or Drill Shop Press ¼ Driver Torque wrench (in-lb or N-m) 2012 Rekluse Motor Sports Rekluse Motor Sports, Inc W Franklin Rd Boise, Idaho support@rekluse.com

2 INCLUDED PARTS Item Item Type Qty 24 Clutch Basket 1 47 M6 Flat-Head Screws Set Screw 1 70 Backing Plate ¼ Drill Bit 1 71 Basket Damper 8 91 Loctite 262 (Red) 1 Visit Rekluse.com/support for a full parts fiche illustration and part numbers Rekluse Motor Sports Rekluse Motor Sports, Inc W Franklin Rd Boise, Idaho support@rekluse.com

3 BASKET OVERVIEW BIKE PREP & DISASSEMBLY 1. Lay the bike on its left side. Catch any fuel that might drain in a suitable container. Remove the clutch cover. 1. Following the procedures in your OEM service manual, remove the existing clutch basket from the engine. NOTE: It is recommended to replace the case cover gasket after re-installing a clutch. 2. Set the OEM basket on a hard surface with the ring gear facing upward. Using a center punch and hammer, punch a divot into the top of each rivet head, taking care to be on center. Rekluse Clutch Basket Installation Guide Page 3

4 3. Use the supplied drill bit to drill out the heads of all the rivets. Set your drill to RPM and use proper cutting fluid or oil for best results. WARNING: Drill only deep enough to pop the rivet head off. Do not damage the steel ring gear; it will be reused. STARTER GEAR INSTALLATION 6. To get the gear to drop into the Rekluse basket most easily, place the basket in the oven at 400 F (200 C) for 15 minutes. Place the starter gear in a freezer for the same duration. 4. Carefully pry the OEM backing plate off of the basket and remove the OEM ring gear. 5. Wearing eye protection, press the starter gear out of the OEM basket. See exception notes below: WARNING: Do not damage the starter gear during disassembly, as it will be used with your new Rekluse Clutch Basket. 7. Place the washer on the gear (only for models that have a washer), remove the basket from the oven, and quickly drop the gear into place. NOTE: The OEM C-clip located on the CRF250R starter gear will not be reused with the Rekluse basket. Honda Owners (except CRF450X, and 09 and previous CRF250R): The starter gear has a spacing washer behind it. This washer WILL be reused with the Rekluse basket Honda CRF250R Owners: The OEM starter gear has a blind retaining ring holding it in place. It will take extra force to press the gear out of the OEM basket and it will probably break the OEM basket during removal. The retaining ring will not be reused with the Rekluse basket. Rekluse Clutch Basket Installation Guide Page 4

5 8. WARNING: Do not press the starter gear without properly bracing the basket in the center! Never push against the basket tangs, or structural damage will occur and your warrantee will be void. Using a shop press or a vice, and properly bracing the basket as shown, press the starter gear into the basket until it is fully seated. Options for a good brace include a section of pipe or a large socket tool. 9. Install the set screw. Use some of the included red Loctite 262 on the threads of the set screw. Torque to the following values: RMS-4112, 4113: 9 in-lbs (1 N-m) RMS-4116, 4145, 4172: 18 in-lbs (2 N-m) 10. Add some engine oil to the cushions and install one per standoff post, followed by the OEM Ring Gear (recessed side out). The ring gear may fit snugly and will likely require using a soft mallet to tap it on until it seats all the way against the basket. Rekluse Clutch Basket Installation Guide Page 5

6 11. Install the Rekluse Backing Plate [#70] and apply the supplied Loctite 262 to each of the M6 screws, threading them into the clutch basket assembly. Tighten to 80 in-lb (9 N-m) in a crisscross pattern to compress the assembly evenly. WARNING: It is critical that you apply Loctite and peen the ends of the screws or they can back out. Rekluse is not responsible for engine damage caused by screws that back out. 12. Using a hammer and center punch, peen the ends of the screws where they come through the bottom-inside of the clutch basket. Be sure to peen the screws. DO NOT peen the aluminum basket. 13. Install the new clutch basket assembly into the engine following the procedures in your OEM service manual Rekluse Motor Sports Rekluse Motor Sports, Inc W Franklin Rd Boise, Idaho support@rekluse.com