Rekluse Clutch Cover User Manual

Introduction

This manual provides essential information for the installation, operation, and maintenance of your Rekluse Clutch Cover, Model RMS-383. This product is specifically designed for KTM 950 and 990 models equipped with the LC8 Engine, manufactured between 2002 and 2013. Please read this manual thoroughly before proceeding with any installation or maintenance to ensure proper function and safety.

The Rekluse clutch cover is engineered for enhanced durability and performance. Constructed from billet aluminum, it offers superior strength and is double hard anodized for increased wear resistance. Its design also provides a greater oil capacity compared to OEM covers.

Product Overview

Figure 1: Rekluse Clutch Cover RMS-383. This image shows the top view of the dark grey, circular clutch cover with the "REKLUSE" logo and a stylized spider emblem in white on its surface. The cover has several bolt holes around its perimeter.

The Rekluse Clutch Cover RMS-383 is a high-performance replacement component for the stock clutch cover on compatible KTM motorcycles. Its robust construction is designed to withstand harsh riding conditions, protecting internal clutch components.

• Material: Billet Aluminum
• Finish: Double Hard Anodized (Polished)
• Enhanced Features: Increased oil capacity compared to OEM covers.

Setup and Installation

Proper installation is crucial for the performance and longevity of your Rekluse Clutch Cover. If you are unsure about any step, it is recommended to seek assistance from a qualified motorcycle mechanic.

Required Tools and Materials:

• Torque wrench
• Socket set (appropriate sizes for clutch cover bolts)
• Drain pan
• New engine oil (refer to your motorcycle's service manual for type and quantity)
• New clutch cover gasket (if not included with the Rekluse cover)
• Clean rags
• Brake cleaner or similar degreaser

Installation Steps:

1. Prepare the Motorcycle: Ensure the engine is cool. Place the motorcycle on a stable stand.
2. Drain Engine Oil: Place a drain pan beneath the engine. Remove the oil drain plug and allow all engine oil to drain completely.
3. Remove Old Clutch Cover: Carefully remove all bolts securing the OEM clutch cover. Gently pry off the old cover. Be prepared for any residual oil to spill.
4. Clean Sealing Surfaces: Thoroughly clean both the engine case and the new Rekluse clutch cover's sealing surfaces. Remove all traces of old gasket material and oil. Use brake cleaner if necessary and allow to dry completely.
5. Install New Gasket: Place a new clutch cover gasket onto the engine case or the new Rekluse cover, ensuring it is correctly aligned.
6. Mount Rekluse Clutch Cover: Carefully position the Rekluse clutch cover onto the engine case, aligning the bolt holes.
7. Install Bolts: Insert all clutch cover bolts. Hand-tighten them first in a crisscross pattern to ensure even pressure.
8. Torque Bolts: Using a torque wrench, tighten the bolts to the specifications outlined in your KTM motorcycle's service manual. Follow the crisscross pattern for final tightening to prevent warping.
9. Refill Engine Oil: Reinstall the oil drain plug with a new crush washer (if applicable) and tighten to specification. Refill the engine with the recommended amount and type of new engine oil. The Rekluse cover has a greater depth, allowing for increased oil capacity; consult your motorcycle's manual for the correct fill level, typically measured via the sight glass or dipstick.
10. Check for Leaks: Start the engine and let it run for a few minutes. Inspect thoroughly for any oil leaks around the new clutch cover.

Warning: Always refer to your specific KTM motorcycle service manual for precise torque specifications and oil capacities. Overtightening bolts can strip threads or crack the cover, while undertightening can lead to oil leaks.

Operating Considerations

The Rekluse Clutch Cover is a protective component and does not alter the operational characteristics of your clutch system. Its primary function is to provide superior protection and increased oil capacity.

• Durability: The billet aluminum construction and double hard anodized finish are designed to withstand impacts from rocks, logs, and other debris encountered during riding.
• Oil Capacity: The increased depth of the cover allows for a slightly higher oil volume, which can contribute to better oil cooling and lubrication under demanding conditions. Ensure your oil level is maintained according to your motorcycle's specifications, accounting for the increased capacity.

Maintenance

Regular inspection and maintenance will ensure the longevity of your Rekluse Clutch Cover and the overall health of your motorcycle's engine.

• Routine Inspection: Periodically inspect the clutch cover for any signs of damage, cracks, or leaks. Check the tightness of the mounting bolts.
• Oil Changes: Follow your motorcycle manufacturer's recommended oil change intervals. When changing oil, inspect the clutch cover gasket for wear and replace if necessary.
• Cleaning: Clean the exterior of the clutch cover with mild soap and water. Avoid harsh chemicals or abrasive cleaners that could damage the anodized finish.

Troubleshooting

This section addresses common issues related to the clutch cover.

If troubleshooting steps do not resolve the issue, contact Rekluse customer support or a certified mechanic.

Specifications

Warranty and Support

For specific warranty information regarding your Rekluse Clutch Cover, please refer to the official Rekluse website or contact their customer service directly. Warranty terms typically cover manufacturing defects.

Customer Support:

If you have questions about installation, operation, or require technical assistance, please contact Rekluse customer support:

• Rekluse Official Website: rekluse.com
• Contact Information: Refer to the "Contact Us" section on the official website for phone numbers or email support.

When contacting support, please have your product model number (RMS-383) and purchase details ready.