problems with Rekluse and Tusk clutch...

[LJ]

I have about 6 rides on my Rekluse with the tusk clutch plates. I figure my rides average 2-3 hours, so I have about 12 to 18 hours on the clutch.

After the install of the Rekluse, I did the 20 minute break-in and had to add another .055" Rekluse metal clutch disk (for a total of 3 disks to get it within the .030" to .042" install gap). I set the gap closer to .030".

I also installed the softer spring at the clutch perch because I do single track more than motocross as per Rekluse recommendations.

Everything worked great and I love the clutch. However, when I changed my oil, I noticed a lot of debri in the filter. This bike ('99 yz 400) always has a clean filter. After the last oil change (I change after every 3 rides), I decided to look at the install gap and it was past the .042" tolerance.

Taking the clutch apart, I noticed the metal plates are blue'd and the clutch disks are below the thickness spec per Yamaha. The spec is around .115" to .121" for disk two and I measure my disks to typically be around .109". I measured .119" for the leftover new Tusk clutch disk I had from the install.

I have the external perch adjuster and believe I set the engagement point correctly (.5" at the end of the clutch lever at 4500 rpm), but I didn't have a tachometer, so I guestimated the rpm, this might be my problem. I've got a tachometer/hour meter on order, so I should be able to do it right next time.

I use Maxima motorcycle oil.

My riding style is to surf the torque curve, meaning I don't rev it hard, I usually ride a gear up. On single track, I'm usually in 2nd or 3rd. 1st is too slow for me. I've been riding for over 25 years and usually one of the fastest ones in my group when I ride single track (unless I'm riding with my old riding Cal Poly Penguins riding buddies, then it's a free for all...). Not bragging, just trying to give info.

My question:

1) Anybody experience excessive wear on the clutch disks with a Rekluse clutch?

1) Has anybody else had a problem the the Rekluse with a non-stock clutch?

2) Should I try a Barnette clutch, or go with stock?

[Dano426]

I was in the same boat as you with my YZ426. I replace my clutch plates (EBC Clutch Kit (Not Kevlar) and installed a Rekluse at the same time. I also notice a lot of metal shavings when first running the bike. I went back in and checked the install gap and it check out OK. After two or three oil changes the medal shavings went away. I figured it was the new clutch plates wearing in and after that, everything was good.

My question:

1) Anybody experience excessive wear on the clutch disks with a Rekluse clutch?

2) Has anybody else had a problem the the Rekluse with a non-stock clutch?

3) Should I try a Barnette clutch, or go with stock?

1) No, but make sure the install gap is within tolerance

2) After a few oil changes everything was fine

3) I had good luck with EBC kit?

I was running Valvoline 20W-50 for four strokes in my YZ426 by recommendation of Rekluse. It works very well and will not break the bank at $2.65 a qt.

I have a feeling that your perch adjuster or clutch cable does not move free enough of the Z-start to pull on the perch adjuster spring, thus resulting in clutch plate wear from the clutch slipping all of the time. I would remove the perch adjuster and use the stock spring for a while until you get it set up the way you want it. I would also give Rekluse a call and review it with them. They have great support and were always willing to help me out.

Good Luck

[bigdrtrdr]

First off, I will go out on a limb here and say, "If its Tusk brand anything its junk"

From brake pads to tire irons I have never seen anything of quality with that mailorder brand on it.

That being said, You need to get the stock clutch parts. Yamaha has great stock plates that last a good long time. I have 6000 miles on my stock friction and drive plates, 2000 of those are with a Rekluse. They are still well in spec's!

I also think that the install gap measurment needs to be a tight fit for the feeler guages. Remember you have like 10 gaps between plates all with a layer of oil to squeeze together to get the proper measurement.

If the first install gap is not set properly you will smoke the clutch, especially a low dollar replacement kit.

Good luck,

Eric

[LJ]

Thanks for the reply!

Maybe I didn't have the perch adjusted correctly. Like I said, I don't have a tachometer, I just reved the engine and adjusted the clutch to have about .5" free play at the end of the lever.

The funny thing is the clutch felt fine to me riding. The only reason I took it apart was because of all the debri in the oil filter. That's when I found the clutch was smoked.

Where did you get the EBC kit?

Somebody suggested to me to use Rottella T for oil. I have a hard time believing that using a different oil would make that big of a difference.

[LJ]

I checked the install gap after 20 minute break in. Perhaps I should have put more miles on it and then checked the install gap. In otherwords, I didn't give it enough time to break in before I re-adjusted the install gap.

[jaggley]

I have an 04 wr450 and had issues with Tusk friction plates with my rekluse. I did go to the Rotella. I found that somewhere past 0.055" is where the gap is big enough that you aren't going anywhere. The perch adjustment is critical and difficult to get right. I have been using the heavy spring in the perch, but am going to try the light one on my next ride.

[jerryls]

I posted about this a couple months ago. Ran stock plates with my Rekluse for over a year and no problems. Put in a new Tusk clutch kit and it ended up frying my clutch basket. Bought a new basket and OEM clutch kit, and no problems.

I learned my lesson. Spend the money now, or spend more money later.

Jerry

[bigdrtrdr]

I posted about this a couple months ago. Ran stock plates with my Rekluse for over a year and no problems. Put in a new Tusk clutch kit and it ended up frying my clutch basket. Bought a new basket and OEM clutch kit, and no problems.

I learned my lesson. Spend the money now, or spend more money later.

Jerry

WORD!

[RichieGoatGruff]

I fried a STOCK clutch pack with a Rekluse. It was because I used to ride a gear or 2 high....Rekluse don't like that! I was in some very vertical single track and was using 3rd, turned the steels and frictions black, she wouldn't move eventually. We had to push up a nasty hill to get her out, wasn't fun...

[LJ]

Thanks for all of the replies!

I posted this in the WR forum and the basic consensus is:

1) Maxima oil does not work with the Rekluse

2) Some people say the Tusk clutch is junk, other's swear by it. Stock seems like a safe bet.

3) Change my riding style (I don't like this one!)

[Country1]

I'm getting ready to instal the z-start on my 04 CFR250X. I've been using Shell Rotilla 5w40 synthetic and was told that I should replace my friction plates. They said the z-start would not work with synthetic oil and I should start with fresh plates and switch to the 15w40 dino Rotilla. I e-mailed and called Rekluse on this and haven't heard back from them?? What do you guys think. I've seen that some say no synth and some say they are using it with no prob. I can't find any oil recomendations in the Rekluse instructions or on there web site. Please give me some opinions. I want to get this thing in!!

Thanks

[bigdrtrdr]

I have used Rotella Synthetic for years with and without an auto clutch, It works fine.

[642MX]

I'm getting ready to instal the z-start on my 04 CFR250X. I've been using Shell Rotilla 5w40 synthetic and was told that I should replace my friction plates. They said the z-start would not work with synthetic oil and I should start with fresh plates and switch to the 15w40 dino Rotilla. I e-mailed and called Rekluse on this and haven't heard back from them?? What do you guys think. I've seen that some say no synth and some say they are using it with no prob. I can't find any oil recomendations in the Rekluse instructions or on there web site. Please give me some opinions. I want to get this thing in!!

Thanks

I was told from Rekluse to use Shell Rotella 15W40 for optimal clutch performance.

[Desracer]

I like the Rekluse and how it works, it does take time to set right. You can call the guys at Rekluse and they are very good to work with on set up. One thing to remember is you still need to shift the gears! Yes you can lug along at low speeds in 3rd but you are killing the clutch plates. Its just a fancy clutch not an automatic transmission. My friends and I have found that we stay in lower gears and rev the engine out more than we did with the stock clutch. I have about 2000 miles on my 05 with the Rekluse, my buddy had 5000 and was .005 loose when we adjusted it.