Remove the entire OEM clutch, except the basket. First, remove the six 10mm
head pressure-plate bolts and springs, then remove the pressure plate. You will
set these aside as the “throw-out” assembly, with bearing and washer, to reuse
with the Rekluse. Pay attention, as the washer you’ll need can stick to the back
side of the pressure plate.
Use a hammer and cold chisel to bend back (open up) the stock bend tab
from around the center clutch-hub nut. If you don’t have a chisel, use a decent-sized flat-blade screwdriver. With the lock washer bent out of the way, use an
impact wrench and a 27mm socket to remove the center hub nut. Remove the
clutch hub with the clutch pack, leaving the large thrust washer on the center of
the clutch basket in the bike.
Separate your OEM fiber and steel clutch plates; you will be reusing all but one
of the fiber friction plates. Soak your new Rekluse EXP disc in engine oil for
five minutes; a zip-lock bag is an easy, mess-free way to do this. Now is also a
good time to inspect your clutch-basket fingers for excessive wear or notching.
Ensure that the thick OEM thrust washer is in place on the shaft sticking
through the clutch basket, then install the 32mm Rekluse clutch hub. With the
clutch hub on the shaft, install the new Rekluse-supplied bend-lock washer and
center nut. The Rekluse center nut must be used in place of the OEM nut, as it
is a special thickness.
Use a clutch-holder tool like the Rekluse one shown (a Motion Pro/EBC one
will work as well). Hold the center hub and torque the 32mm Rekluse hub nut.
Torque the nut to 50 foot-pounds, then bend both lock tabs up with a pair of
channel-lock pliers. Do not over-torque! If you don’t have a clutch-holder tool,
this can be accomplished with a clutch pack installed and a helper applying the
Install the clutch pack. Start with the single, thinner steel drive plate, then add
a stock friction plate; alternate between the thick Rekluse steel drive plates
and stock friction plates. Once you have seven friction plates installed and the
seventh “thick” steel drive plate on the outside, it is time to install the EXP
disc. With the EXP disc on the outside, install the throw-out assembly; it will go
bushing, bearing and then washer on the outermost surface.
Place the six-toothed steel lining
plate onto the Rekluse pressure
plate. A light film of engine oil
between them will help them stick
together and ease the installation
process. The six teeth on the lining
plate index into the respective slots
on the pressure plate. Install this
pressure plate subassembly into your
clutch. Be sure that the lining plate
stays in place, and then install the
new Rekluse pressure plate, springs
with alignment sleeves and M6
screws. Torque to 9 foot-pounds.