A forum for owners of Yamaha TTR250 trail and enduro bikes!

Great stuff. Let us all know how you get on

Actions speak louder than words, or so it's said!

Take a look at this explanation of a Rekluse clutch system:-

Martyn

Hi petenz, very interesting project. please keep us informed and give details of the installation.

My personal opinion is that the TTR250 would be a very nice bike with a working rekluse (if it fits).
The rekluse seems to work well on various bikes including ktm etc.

I also have a postie bike (ct110) which has seen a lot of dirt action.
They only have a 4 speed (fairly close ratio) gearbox, no power to speak of, and an auto clutch.
the auto clutch saves the day for it and means no stalling.

The postie bike also offers something the rekluse does not - auto engagement on gear change.
But actually this is a pain - you get clunky gear changes unless you deliberately control the
clutch disengagement with fine movement of the gear lever (as there is no clutch lever).
Also, after an "oops" on a hill the bike won't stall, which is good, BUT the auto clutch
take up is not enough to get going - you have to do the fiddly gear lever trick to get revs and slippage.

So that is why a rekluse with full normal clutch override would be good.
If I had one I would use the manual clutch on every gear change.

Below are a list of pros and cons for the rekluse.
It would be nice to get your comments on them after you have it installed and tested..

PROS

no need to cover the clutch lever in tricky slow going;
no need to "find neutral" when stopping temporarily;
no engine braking - so no need to hold clutch in on long slow descents to avoid rear wheel lockup;
inappropriately high gears can sometimes be used without too much problem.

CONS

bump starting may not be feasible [but probably needed less, so a moot point];
bike may roll back on a hill if parked and turned off in gear;
clutch may overheat if allowed to slip too much;
need to relearn best ways of lifting front wheel over logs etc at slow speeds.
no engine braking [a matter of opinion, I personally like brake levers to control braking rather than the engine].

petenz wrote:

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I have ordered a Rekluse EXP for the TTR...

(For those who don't know what a Rekluse clutch

dose.... it's a full auto clutch , works the same as the Honda CT110 & posties

have... but with one diffrents... you still retain the manual clutch aswell..)

Rekluse don't make a clutch for the TTR... So I'm going to use the WR250F

unit.. As the WR250 / TTR250 / XT250 all share the same friction plates..

The Rekluse EXP is the same shape as the friction plates but thicker...

I done the same to my XT660R... used a WR450 Rekluse EXP as the XTR & WR450

use the same friction plates.. the XTR took a bit of setting up as the XT & WR make

a totaly diffrent type of power... Had to change to heavyer weight wedges use the

lightest springs tha came with the Rekluse...

So I'm hopeing this will be  easyer to tune , as the motors are closer to the type

of power out put... WR250 will be a bit faster reving..So I thinking I will prob

need the lightest springs in the EXP unit for the TTR..

 

Pic of the WR450 Rekluse EXP in the XT660R clutch..

 

---

 Please keep us updated on  your progress!

I haven't use a Rekluse but thought it would be a nice upgrade, so I was a bit envious of the WR guys. Hope it works!

A few bits turned up... No clutch as yet...

B&B bash plate / Korba link / Smaller flashers..

Have also ordered a small digital speedo / rev counter....

 http://www.dan-moto.com/DM_INT/danmoto-nano-product-134.html

 

 

-- Edited by petenz on Sunday 14th of July 2013 01:24:11 AM

Is that the whole kit? There isn't that much to it.

Please keep us posted, I have been thinking about how nice MY Rekluse-equipped TTR would be!

Watched the videos, installation seems straight forward though I don't see exactly how the engage myself. I'm thinking the centrifugal force expands the Rekluse pack?

Then, I did a little exploring in the parts fiche &  it looks as though the YZ125 (Rekluse is available) & TTR250 share the same part numbers for both friction & plate discs, so it WILL fit! The TTR just used a few less discs.

Eager to see this work.

petenz wrote:

---

=

TDVT...

The YZ125 EXP would be set up for the wrong type of power delivery for the TTR...

And another thing to take into account is the primary reduction ratio... ie- how fast the

clutch spins compaired to the crank...

 

 

 

 

 

-- Edited by petenz on Thursday 18th of July 2013 07:17:06 AM

-- Edited by petenz on Thursday 18th of July 2013 09:17:38 AM

---

Makes sense that the 125 would be set up differently; 2-stroke, etc. but it was positive confirmation that they are physically the same size. Then I re-read your original post & saw that you mentioned that the WR/XR & TTR have that same size plates. Old news.

I am guessing the Rekluse is 3 plates thick to fit in the stack with a drive plate on each side? Will you mount it in the middle of the stack or on the outside?

 

Got it instaled... The WR250F Rekluse EXP unit is a straight drop in fit for the TTR250....

I set the clutch to stall at low rpms buy removeing 3 of the red medium springs & replaced

them with the 3 lightest silver springs .. So it now has 3 red & 3 silver springs in it..

Setting it to stall at low rpms should will make it better for slow rideing/river crossing etc..

 

You need to remove 3 steel plates & 4 fricton plates from the clutch stack , after the Rekluse unit

is placed in you put 1 steel & 1 fricton plate back in... leaveing you with 2 steel & 3 fricton plates omited

from the stack...."The Rekluse unit should be between 2 steel plates"

I had to back the adjuster on the pressure plate off to let the stack ingauge... set it with a slight amount

of free play... then it's just put the 5 rekluse clutch springs in.... Which are shorter than the TTR ones but stronger..

It's all pretty easy & straight foward.... then just follow the instuctions that come with the unit for the final

set up after you have the bike running ...

now I'm waiting for a longer clutch cable to turn up from Totalyttrs.. as I have put fat bars & risers on , before I can

take it for a ride......

 

 

the Rekluse clutch springs & the un-used clutch plates

 

Setting the clutch lock up rpms...... Replace 3 of the 6 red springs with the 3 silver springs

to give clutch lock up at low rpms....

 

-- Edited by petenz on Saturday 20th of July 2013 02:02:41 AM

-- Edited by petenz on Saturday 20th of July 2013 02:04:31 AM

-- Edited by petenz on Saturday 20th of July 2013 02:08:12 AM

-- Edited by petenz on Saturday 20th of July 2013 02:22:19 AM

LRJ wrote:

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As a fairly novice rider, I feel uncomfortable going down steep inclines with the Rekluse clutch. I just don't feel like I have as much control without the help of engine braking.

---

 I quess it's what your are use to.... I have always just used the brakes...for me its a carry over from rideing trials..

Anyway i;m going to pull the TTR apart 2day & see if it dose fit....

Looks great. Keep us posted!

Got it going & had a play to set the clutch... works greats..

Can hold the front brake on while idleing in 1st.... wined the throttle

and it will spin the rear wheel on dry cement & push the locked up front

along the ground.... I would say theres no clutch slip after it ingauges..

So All done & dusted.... now whats next?..

 

petenz wrote:

---

Got it going & had a play to set the clutch... works greats..

Can hold the front brake on while idleing in 1st.... wined the throttle

and it will spin the rear wheel on dry cement & push the locked up front

along the ground.... I would say theres no clutch slip after it ingauges..

So All done & dusted.... now whats next?..

 

---

 Sounds like you hit the set-up first try. I had figured the Rekluse was a more substantial unit & wouldn't have thought to explore it as you did. Definitely moving this WAY up the list for my TTR.

You had mentioned USD forks which Brian & I have talked about somewhat though neither of us has taken the plunge. If you do the conversion please keep us informed.

So to further fan the flames I will share a VERY back burner idea, maybe you will be interested. I have been contemplating installing a WR/YZ swingarm & shock (though my stock shock is working fine for now) & have collected a few part to that end. I was initially interested when I was looking for tuning info/parts for the TTR & the would come across heaps of WR/YZ stuff. That combined with the replacement cost of a stock TTR shock & the glut of cheap used WR/YZ parts available on ebay has me in the planning stages.

I have 2 YZ frames on hand (a 426 & a 125) to use to make a jig to keeping the pick-up point geometry the same. I am thinking I might have to change calipers (not sure), make some sort of adapters for the axle (same diameter, hope to keep the TTR wheel) & re-weld mounts for the suspension link on the TTR frame.

This will also necessitate moving the battery but I will get a lightweight when this one gives it up & find a new spot for it.

The thought a WR/YZ-suspended, TTR325 with a Rekluse sounds like a fantastic, low maintenance bike to me.

TDVT wrote:

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Also meant to ask why you used the billet basket? Googled it......a bit pricey.

---

 No I havn't use a billet .. what I was talking about.....  I have read that the rekluse can speed up clutch basket ware...

If it did I would replace the basket with a WR250F billet basket... Has thicker fingers...

had the bike out 2day.. first real ride with the Rekluse in it..

not good... way way to much clutch slip..

I think the prob is the clutch springs that came with the unit

they were a bit shorter than the TTR ones... So have less pre-load

on them when tightened up... 

will sorce some longer heaver springs, I have a ful set of heavy duty

clutch springs for the XT660 & also the Rekluse springs that came with

the WR450 unit I have in the XT660...Will see if they will fit..

If I have no luck with those I will get a set of heavy duty TTR springs..

So if yer thinking about one for yer TTR... hold off till I get this thing sorted

then I can let yer know what to use....

 

Just put a set of EBC heavy duty TTR250 clutch springs in...
See if it makes a diffrents this week end...
EBC part number - CSK014

thanks for keeping us in the loop, petenz.

after your final (?) setup, did you notice a heavier clutch pull when de-clutching for gear changes?

I have lowered the gearing from 14/44.

Now has 13/47... the bike really hooks up now

& the clutch locks up a few 100 rpms above idle..

will lift the front with out to much rider input...

The only thing I can't get it to do is a front/rear wheel hop

for clearing logs/vertical steps... No matter how much yer load

the suspention the power right of idle just dosn't have

enough snap to it.. I guess the bash plate will get a work out....

These TTRs are a pretty under rated bike...for what they are..

-- Edited by petenz on Saturday 24th of August 2013 10:07:05 AM

I'm sold on them.... they really come into there own in tight stuff / river crossing / mud...

I have not tryed.... But with the EXP unit that I have... If you back the clutch cable off

at the hand lever the Rekluse fully ingauges so you can push start....

The guy with the KTM may have had the Rekluse Z-Start pro , they use up to 28 ball bearings

as the weights traveling in tappered slots... you tune the clutch by how meany ball bearings

you use...

TTRfan wrote:

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Any chance of another update Pete, with a reminder of the pros and cons of the Rekluse as you have found it, please?

Brian

---

 Can do...........

It's still going strong.. Had no issue with it after getting it set up..

lowering to gearing to 13/47 to make it easyer to keep the revs up

has made it lock up quicker... You need to be a bit heavy handed on

the throttle so the motor dosn't labour.. the clutch dosn't like that..

Got to keep the motor spining free so the clutch speed is up & the

weights can generate enough force...

If you ride tight terrain the Rekluse is just magic... There is very little

benifit from it in open fast terrain...

I have just got back from a 2 day trip around the high country on

my XT660R that also has a Rekluse EXP in it... clutch made it

so easy to ride on the tight rough tracks & gravel roads..

the XT is a170kg/400lb bike with me & gear prob pushing 600lbs..

The clutch handled it with no issues...

The only thing I have read about them is you do need to change the oil

& filter quite often as the oil dose get a lot of clutch fiber in it... So friction

plate wear will be a lot higher... On the TTR I do oil/filter about every 8/10hours..

the XT every 1500/2000km....

 

Yes .. they are good things... if you have a use for them.....

 

Quick update...

I have had the Rekluse in just over a year now...
Not had to open the motor since I instaled it...
The only mod I have made to the system since is a
clutch arm stop to take the strain of the clutch
cable & give finer adjustment of the clutch as well
as remove the incossitanty of useing the cable to
hold the clutch stack slightly open..

Done a 40km forest single track ride on the weekend..
Now can't imagine riding terrain like that with out
the Rekluse now.. Wet sticky ground & some snow higher up..
Being able to stop on a hill/climb & start with out the bike
wheel spinning/ trying to wheel stand or bogging the motor
just 1st gear bring the revs on & all yer get is traction...

It's feels almost like cheating..

couple pics of how I made the clutch arm stop....

 

-- Edited by petenz on Monday 14th of March 2016 05:24:15 AM

Yes ... had to put a longer 10mm bolt though....

Rekluse make a left hand rear brake master cylinder...
once you have got used to left hand brakeing you will
never want a foot brake again....gives control your foot
can't come close to...

I have seen home made units that use a cable to the rear brake
foot lever... then you still have foot brake aswell as left hand..


pete