Rekluse z-Start Install Supplement For the CRF250X

1. Required Tools: In addition to those mentioned in the instructions, I needed the following:

Needle Nose Pliers: Step 3, to remove the circlip on the brake pedal bolt

8mm Allen wrench: Step 3, to remove the brake pedal bolt Work rags or towels (see Photo): Step 4b, to prevent parts from being dropped into the engine or skid plate.

1/4" socket: Step 10, to drive the included T10 Torx head driver

Magnet: Step 12, to distinguish the steel balls from the tungsten balls if mixed

2. Instructions Error: Step 3: Change "rear brake lever" to read "rear brake pedal".

3. Instructions Error Step 5: Note: Make sure the stock throw-out ball spacer remains in the transmission output shaft. Correction: The Honda CRF250X has no throw-out ball spacer.

4. Instructions Error Step 6: The instructions seem to indicate that the clutch pack should be reinstalled after removing the clutch boss spring and boss spring seat. Do not reinstall the clutch disks until step 7. It's difficult enough to remove the oily clutch plates and discs once, without having to remove them again in Step 7.

5. Instructions Clarification Step 7: I was never really sure when the newly assembled clutch pack was supposed to be installed in the clutch basket. Do it before moving on to Step 8.

6. Instructions Suggestion Step 8: Using a drop of oil on each shim (washer) will help them stay in place later when the studs are removed. Also, only five of the ten shims are used in the 250X application.

7. Instructions Clarification Step 9: It should be stated at this point that the Lower Assembly has to be removed (disassembled) from the z-Start clutch assembly.

8. Instructions Clarification Step 9: It should be noted that the Lower Assembly has two sets of five countersunk holes. If the first set doesn't line up with the studs, rotate the plate to the second set of holes.

9. Helpful Addition Step 12: When removing the steel and tungsten balls from their bags, place them in a tray or on a thick cloth to prevent them from rolling around. If the steel balls should somehow become mixed in with the tungsten balls, the steel balls can be easily selected from the tungsten balls by using a magnet.

10. Photo Clarification Step 14: The Pressure Plate shown in the photo has 12 holes, so it does not match the one supplied in the kit with 10 holes, so it is impossible to follow the instructions in that step. It is important that some holes be marked, however, since the screws in the marked holes have to be removed and replaced later with Loctite.

11. Instructions Clarification: There is no T10 torx key included in the kit. It's a T10 torx driver bit for a 1/4" driver.

Finally, going back to Step 1, paragraph 2, regarding removing the clutch lever: If the Honda CRF250X clutch lever is removed, this will disable the electric starter. On the CRF250X, the electric starter will engage only when the starter button is pressed, and the clutch lever is pulled in far enough to disengage the clutch. The secondary starter switch is located inside the clutch lever perch. This is not a problem, however, if the optional Perch Adjuster is used in conjunction with the auto clutch.

Installation Supplement by: Gordon L. Banks, October 2004
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