Too much freeplay gain with exp 2.0

11 replies to this topic
  • nardski659

Posted October 23, 2013 - 02:19 PM


Hey guys, I have a 06 yz450 and I put a rekluse exp2.0 in it yesterday but I had way too much freeplay gain in the lever, probably at least an inch. Has anyone had this problem or does anyone have a solution for my problem? Thanks in advance for any help, I guess I'll call rekluse tomorrow, I hear their customer service is great too

  • nardski659

Posted October 23, 2013 - 02:20 PM


Forgot to mention I turned the adjuster as far as I could but it didn't seem to help

  • JLB943

Posted October 24, 2013 - 07:50 AM


Are the clutch plates worn a lot? Are you certain that you have put the correct number of steels and friction plates in according to the diagram? These are the things that I would check. I assume you have put the rubber band on the lever and are revving the bike at it is travelling more than 1/8 to 1/4".

  • nardski659

Posted October 24, 2013 - 02:25 PM


The clutch is almost new as the bike has about 15 hours on it, I am sure I put the correct number of disks in, I did realize after tht I reused the stock pressure plate springs, I swapped those out with the rekluse blue ones but haven't had a chance to try it. Not sure if those would make a difference or not

  • blurz28

Posted October 27, 2013 - 09:17 PM


You probably have too many friction disks in.....
I have an 06 YZ 450 and put an exp 2.0 last week.
I put 6 under the exp and 1 on the outside..... And I had a huge amount of play and couldn't get it to engage properly.
I did it in a hurry cause I was excited to try it out.
Then I sat down and read I was supposed to use 6 stock friction disks - 5 under and 1 above the exp....
And don't forget the extra spacer on the throwout.....

An easy way to tell if it's using the right # is you should have 3 stock friction/steel disks left over

  • Monk

Posted October 27, 2013 - 09:50 PM


Read the manual again. The answer is there....

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  • nardski659

Posted November 04, 2013 - 03:39 PM


I ended up getting enough adjustment but it was pretty much maxed out. I'll have to count the disks again this weekend. Thanks for the help

  • nardski659

Posted November 04, 2013 - 03:48 PM


And you mean the washer on the throw out right? I don't remember any extra spacer in the kit

  • blurz28

Posted November 04, 2013 - 08:54 PM


Yeah, there should be a 2-3 mm thick spacer in the kit that goes on the throwout.

  • nardski659

Posted November 05, 2013 - 11:26 AM


You were right, I looked through my spare parts and there it was, it helped a bit with the adjustment. Thanks again for the info

  • blurz28

Posted November 05, 2013 - 01:25 PM


Glad it helped

  • nardski659

Posted November 05, 2013 - 02:47 PM


I did run into a small snag though. When I was reinstalling the throw-out, I misplaced the little steel ball that fits inside it, went to the local parts store and got a new one but I couldn't find the other one anywhere. This might sound really dumb but if it fell into the motor is it going to trash it? I just ordered a mag oil drain plug in hopes of pulling it out in one piece. I'm really hoping not to have to tear the engine apart to look for it. I was working on it in my driveway on a hill so chances are it went for a roll but it's still got me worried

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