Installing a Rekluse Z-Start Pro with Pictures
  • tintman
    Posts:27
    Joined:Wed Apr 18, 2007 6:40 pm
    Installing a Rekluse Z-Start Pro with Pictures

    by tintman » Thu Sep 13, 2007 5:27 am

    I was a bit worried about doing this install myself as I'd never even taken the clutch cover of a bike before but the Rekluse website assured me it was a simple install, so this is what I did.

    Disconnect clutch cable turn fuel off and lay bike on left hand side(I took clutch lever off as I was installing a left hand rear brake with 2 finger clutch over-ride)
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    Remove clutch cover
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    Remove bolts and springs from pressure plate and remove pressure plate, clutch throw out and clutch plates (keep clutch friction plates for re-installation later.
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    Bend the tabs of the retainer ring away fron the clutch center hub and undo hub nut. I found holding the rear brake on with the bike in 4th gear and using a large breaker bar worked well or use a rattle gun if you have one.

    This is what you are left with once you remove the center clutch hub.
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    Your half way there now.

    Now install the new center clutch hub that comes in the Z-start pro kit, make sure you put the original thrust washer that was under the original clutch hub back in first.
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    Install the locking tab that comes in the kit with the flat washer from the same pack on followed by the original center clutch nut which I did up tight(you might want to get the actual torque spec)
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    Install the clutch plates starting with a steel drive plate supplied in the kit followed by a friction plate removed earlier untill 8 of each are fitted.
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    Install the inner(lower) section of the Rekluse centre clutch hub.
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    Install the retaining snap ring that secures the inner hub to the outer section.
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    Re-install the original throw out with bearing with supplied rekluse throw out spacer and spring carrier on top.
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    Refer to tuning chart and decide what spring will suit your requirements and install spring over spring carrier mounted on throw out.
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    Cover any larger gaps between engine case and clutch basket with tape incase you drop something in the next few steps.

    Away from bike place steel balls into slots of Rekluse pressure plate(check balls are correct size and that you have 30 of them, the ones supplied in my kit were a size to big and I only had 27 of them. Rekluse did not reply to my email as to why but the local bearing shop fixed me up with the correct size balls)

    This picture shows how it will look if the balls are the wrong size, notice the closest ball is a Tungsten Carbide ball which you get 5 of in the kit which is the size the steel balls should be.
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    This is how it should look with the correct size balls.
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    Place Recluse top plate over pressure plate and with holes aligned screw to clutch assembly with torx screws and loctite provided.
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    With supplied wire guages check friction plate clearance.

    Install clutch cover(after modifying slightly as per instructions or purchase deeper Rekluse bling cover)

    Job done, all that is needed is to top up gearbox oil as you will need a bit more, adjust clutch lever freeplay with engine running and then break in clutch.

    I found the instructions fairly easy to follow but they could have done with a few more pictures. There is also a confusing error at step 22 it should say skip to step 24 not 23.
    Last edited by tintman on Tue Sep 18, 2007 3:32 am, edited 1 time in total.
  • [email protected]
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    Joined:Sun Aug 14, 2005 6:21 pm

    by [email protected] » Mon Sep 17, 2007 9:32 am

    That'd be a great stickie, very nice job. Doug
    Last edited by [email protected] on Wed Nov 05, 2008 5:57 pm, edited 1 time in total.
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    Monkeywrench
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    by Monkeywrench » Mon Sep 17, 2007 5:29 pm

    My highest compliments on the clean & neat appearance of your garage! =D> Good maintanance starts with a great place to do it, and it looks like you have both under your wing there. ;)

    Have to admit my first reaction when I see a CRF on its side is to want to pick it up, though. ;) (what? bleeding elbow? yeh I got another one, help me pick up my bike!!!) :lol: but you did this one on purpose (gently) so it's ok. ;)
    2006 450R
  • tintman
    Posts:27
    Joined:Wed Apr 18, 2007 6:40 pm

    by tintman » Tue Sep 18, 2007 3:19 am

    Monkeywrench wrote:My highest compliments on the clean & neat appearance of your garage! =D> Good maintanance starts with a great place to do it, and it looks like you have both under your wing there. ;)

    Have to admit my first reaction when I see a CRF on its side is to want to pick it up, though. ;) (what? bleeding elbow? yeh I got another one, help me pick up my bike!!!) :lol: but you did this one on purpose (gently) so it's ok. ;)

    Yes, it feels really strange to lay the bike on it's side intentionally.

    The garage should be tidier as it is a new house and we only moved in 3 weeks ago but I am always in the middle of doing too many things at once.
  • tintman
    Posts:27
    Joined:Wed Apr 18, 2007 6:40 pm

    Update

    by tintman » Thu Nov 08, 2007 12:34 am

    Since installing an Athena 280 kit and changing the rear sprocket to a 50t I found the clutch was slipping under low rpm acceleration so have installed the Tungsten Carbide balls and now the balance feels perfect.
  • Captain Kirk
    Posts:1
    Joined:Wed Dec 24, 2008 7:33 pm

    by Captain Kirk » Wed Dec 24, 2008 7:39 pm

    Great write up. This is my winter project and I'll use this as my guide.
    Makes me want to paint my garage floor first.
    Both me and my bike get tired trail riding so seeing a bike laying down is normal to me. Mine always likes to take breaks during a tough day of riding. I let it rest for a bit while it catches its breath. I'm always the one wanting to continue but noooo... it just takes a break and lays down when it wants.
    Captain
  • CRFX310
    Posts:26
    Joined:Thu Dec 25, 2008 12:41 am

    by CRFX310 » Tue Jan 27, 2009 3:38 am

    Excellent documentation-i wish rekuses instructions would have been that clear 4 years ago when i installed mine in my 450r-im in the process of installing the athena kit in my 250x right now and am curious how that went-are you pleased and what did it do to your jetting? thanks and keep up the good work!
  • tintman
    Posts:27
    Joined:Wed Apr 18, 2007 6:40 pm

    by tintman » Tue Jan 27, 2009 12:11 pm

    The Athena kit was fitted when I got the valves done so sorry can't give you any tips on that one. It was very straight forward once they had the head off, didn't even charge me to do it.

    I didn't need a jetting change, still used the reccomended setup from the JD kit.
  • bhoth
    Posts:11
    Joined:Sat Sep 15, 2007 6:29 am

    by bhoth » Wed Mar 18, 2009 1:58 pm

    What size is the center clutch nut? (I have heard 27mm and I have heard 30mm) I am going to be adding the Rekluse Pro kit and I want to make sure I have all the tools I need when the kit shows up.

    Thanks,
  • [email protected]
    Posts:5039
    Joined:Sun Aug 14, 2005 6:21 pm

    by [email protected] » Thu Mar 19, 2009 3:18 am

    Give Rekluse a call.
    I've installed several Pro's in different brands and don't remember. It is one of the two however. Doug
  • tintman
    Posts:27
    Joined:Wed Apr 18, 2007 6:40 pm

    by tintman » Thu Mar 19, 2009 3:42 am

    bhoth wrote:What size is the center clutch nut? (I have heard 27mm and I have heard 30mm) I am going to be adding the Rekluse Pro kit and I want to make sure I have all the tools I need when the kit shows up.

    Thanks,


    It must be a 27 because I don't own a 30. Sorry I can't tell you 100%
  • halgaruk
    Posts:9
    Joined:Sat May 09, 2009 4:47 am

    by halgaruk » Wed May 27, 2009 9:30 am

    The Rekluse auto clutch for my CRF150R has just arrived this morning, and baffled by the Instructions I've browsed among the Forum to find this.

    My quick question is, will I need to replace anything... like gaskets, during the Install?

    OR

    Is it just a case of simply, taking the clutch apart and installing the Rekluse without the need of ordering parts in.

    Any advice and help would be appreciated.

    Thanks in advance!

    Gary
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    motosicko
    Posts:1348
    Joined:Tue Sep 25, 2007 7:20 am

    by motosicko » Wed May 27, 2009 11:41 am

    I ended up needing to get a stock right side crankcase covergasket for our 150. If you are careful and don't tear the existing gasket you can re-use it, but should order one just in case it tears, mine did. :cry:
    Last edited by motosicko on Thu May 28, 2009 9:01 am, edited 1 time in total.
    "There are old racers
    and there are bold racers,
    but there are no old, bold racers who don't walk funny."
  • halgaruk
    Posts:9
    Joined:Sat May 09, 2009 4:47 am

    by halgaruk » Wed May 27, 2009 4:16 pm

    Nick Susco wrote:I ended up needing to get a stock right side crankcase cover for our 150. If you are careful and don't tear the existing gasket you can re-use it, but should order one just in case it tears, mine did. :cry:


    Thanks Nick...

    Why did you need to get a Stock ride side crank case cover?

    Think I better order a spare gasket, just incase....

    ATB

    Gary
  • halgaruk
    Posts:9
    Joined:Sat May 09, 2009 4:47 am

    by halgaruk » Thu May 28, 2009 5:49 am

    Yes, my gasket teared aswell, so have ordered a new one.

    :(

    Now I have to wait for it to arrive before I can finish install
    2007 CRF150R

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