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Post Info TOPIC: TTR with a Rekluse EXP clutch..


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TTR with a Rekluse EXP clutch..
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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..

 



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Great stuff. Let us all know how you get on

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I still don't understand what this clutch actually does, could you explain what effect it has when riding please.thanks.


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

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

Martyn



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Thanks Cubber,that explains alot.


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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].



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brindabella wrote:

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].


CONS...

1.. You can bump start with the EXP unit.... Need to make a slight adjustment at the clutch lever...

2... ? not tryed with the XTR....

3.... Is a possability.... Correct clutch set up should stop slipping after ingaugement... the EXP unit inserts enough pressure

to compress the heavy duty clutch springs that come with the clutch.. You can feel & see it...Hold slight pressure on the clutch lever &

rev the motor  the clutch lever moves in towards the hand grip as the Rekluse unit exspands compressing the clutch

springs & tightening the clutch stack...

4.... same as normal.... the manual clutch still works....

5.. No biggy for me... always use the brakes not the motor... the motor has no idea

what the rear wheel is doing.... but I do...



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petenz wrote:

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!



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TDVT wrote:

 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!


I know a few people with Rekluse clutches on their dirt bikes and confess to being a tad envious!

I will be another owner watching this thread with great interest biggrin

Brian 



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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

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The Clutch arrived 2day.....

It comes with very heavy clutch spring & 2 sets

of small springs for tuning how & at what revs

it locks up... the 2 sets of spring give 3 tuning

options....

 6 lightest springs..... lock up at lowest revs..

3 light / 3 heavy springs..... med lock up.. " how it comes from Rekluse"

6 heavy springs..... lock up at higher revs...

 

Rekluse part number... 

 



-- Edited by petenz on Wednesday 17th of July 2013 07:12:22 AM

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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!



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More info here - http://rekluse.com/198-6071_Setup_Sheet_RMS-6071.pdf

Still can't quite see how it works. Some pics of the installation process and completed installation would be appreciated!

Brian



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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.



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TTRfan wrote:

More info here - http://rekluse.com/198-6071_Setup_Sheet_RMS-6071.pdf

Still can't quite see how it works. Some pics of the installation process and completed installation would be appreciated!

Brian


Brian

 The unit has 6 wedge weights in the middle... that  run on 3 ball bearing on each side of each wedge weight....

The ball are in tappered slots ... As the revs increass the weights travel out exspanding the rekluse unit & compressing

the plates in the clutch... After the rekluse unit has fully exspanded & the clutch is 

driveing ... you can then pull the clutch lever to open the clutch... manual clutch oparation...

The unit exspands about 2/2.5mm ..

=======================================================================================

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

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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?

 



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TDVT wrote:
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?

 


 heres the thing.... the fitment link Brian posted & the fitment sheet that came with the clutch are diffrent as to where the rekluse

unit sits in the clutch pack.... my sheet shows it 1 steel drive plate & 1 fricton plate in..... Where the fitment link brian posted shows

the total oppisite... the WR450 unit i put in my XT660R ... sheet shows the same as this one that came with the clutch...



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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

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LRJ


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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.

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LRJ wrote:

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....



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TDVT wrote:

This is excellent!

Looking forward to your ride report, especially regarding the spring set-up.

An academic question since you already have a Rekluse in your other bike, do the remaining friction plates wear out quicker since there are fewer of them left?

And does the Rekluse have friction material on it? Sort of looks like it does in the pics.

Thanks for trying this & for taking the time to keep us in the loop.


 the only thing I have read.. Is the Rekluse can speed up clutch basket ware... the fingers notching faster... If that dose happen I would

put a Hinton WR250F billit basket on to the TTR gear.. But Its going to take while for the basket to ware..

I will say I have not seen notched baskets on lower powered trail type motors... It seems to happen more on higher HP

out put motors...

yes there is a thin layer of fricton material on the unit... I looked at that when I done the XT660R with the WR450 unit..

figgered if it was to ware of .. you could put the Rekluse unit between 2 fricton plates...

Any way only time will tell...

 



-- Edited by petenz on Sunday 21st of July 2013 10:14:17 AM

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Looks great. Keep us posted!

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This is excellent!

Looking forward to your ride report, especially regarding the spring set-up.

An academic question since you already have a Rekluse in your other bike, do the remaining friction plates wear out quicker since there are fewer of them left?

And does the Rekluse have friction material on it? Sort of looks like it does in the pics.

Thanks for trying this & for taking the time to keep us in the loop.



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

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..no

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



 



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petenz wrote:

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

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..no

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


 Excellent news and thanks for the feedback with pics - a great help to budding Rekluse buyers - which might include me wink

What next?

I don't think we have a detailed report with good step by step pics of fitting WR or YZ forks............. If we have, someone please correct me and bump the thread biggrin

Brian



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petenz wrote:

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

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..no

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



 


 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.



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



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TDVT wrote:

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...



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petenz wrote:
TDVT wrote:

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...


Oops,  I need to read more slowly.



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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....

 



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Thanks for the update. Would shimming the springs work if you can't find replacements?

Had a ride today with a guy who has a brand new Beta 450 with a Rekluse. He's only had it since the beginning of the week but likes the Rekluse (& the bike) pretty well so far.

 

Keep us posted.



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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

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It now works... just need the heavyer EBC clutch springs...
Done a organised trail ride 2day... (more of a Enduro)
40km track all under trees on hills... I pounded that clutch
and it loved it.... One thing I did notice is you need to be
heavy handed on the throttle... to get the revs up as fast
as possable so it bits hard.. the track was so tight and hilly
I never really got any higher than 2nd gear .. but do still
have the 13/44 gearing on.. needs to be lowered...

The guy I was rideing with had a gopro... So hopefully
I can get a vid posted...

 

The thing with the Rekluse clutch.. If yer just ride easy trails/ gravel roads

etc there is not a lot of benifit from fitting the Rekluse...



-- Edited by petenz on Sunday 11th of August 2013 09:19:51 AM

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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?

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brindabella wrote:

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?


 yes the clutch pull is heavier... but not overly heavy



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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

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Wondering if you've gotten some more seat time with the Rekluse & have any more observations?

I did a ride with a few Rekluse-equipped bikes this past weekend. Same story, they were apprehensive to get them, now they wouldn't be with out.

One KTM in particular was trying to bump-start his bike but was unable to, but I am thinking that may be a different model than what you have installed. Does the bump-start actually work on the TTR (no kicker on the TTR here in the US)?



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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...



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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



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TTRfan wrote:

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.....

 



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Nice reading


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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..

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Hi all. Thanks to Pete's experimentation I've done the same mod to mine. I used the EBC springs too. Been doing a mix of rpad and trail riding for just over a week. I'm thinking of switching to the lighter tuning springs for earlier engagement. I'll also make a clutch arm stop adjuster to take the tension off the cable. So far I love the set up and can see the benefits over the cons. I can't clutch up a wheelie any more though, and I've given it a lot of goes...

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

 



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

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Thanks Pete. That's perfect. Did you run a longer threaded rod for the engine mount? Does it go through to the other side of the bike?

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

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I plan to order a Rekluse and I just wanted to confirm that those running the Rekluse clutch haven't encountered any issues? I can't find the "RMS-6071 EXP clutch 2.0" on their Website so I plan to just call them and order this part along with the EBC CSK014 HD Springs. My bike is used only for tight technical high elevation single track in Idaho Utah and Wyoming. I'm running 12/52 Gearing.

I also want to install a LHRB so if anyone has a specific brand that seems to fit and work well I would like to know any details on the installation also.

Any Suggestions/Comments appreciated.

Thanks

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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

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Pete,

So with my 2006 all I need to order is the Rekluse "RMS-6071 EXP 2.0 Clutch" use the lightest Springs that cam with the kit and also install "EBC CSK104 HD Springs" and that takes care of the Clutch correct?

Which Rekluse LHRB do I need to order since they don't list one for the TTR?

Thanks for help!

Brett

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yes thats all you need for the clutch..

any of there master cylinders that have to correct size banjo fittings should work..
hydruilic clutch master cylinder might work and be cheap from a motorbike wreckers..


When you adjust the clutch do it on a hot motor/hot oil...cold motor/oil gives to much drag
so you get a false setting and when the oil heats up the unit slips more than it should..


..

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