So, while I was installing my Rekluse EXP 2.0....

[johnny6speed]

I learned while doing my first clutch R&R on a dirtbike, not to use a BFTqW. ?

[zlathim]

Bummer.

If the shoulder bottomed and not the shank, it should come out fairly easily. If you have a left handed drill bit the right size, that would be a good place to start.

Good luck ( this is of course assuming that you haven't already extracted the broken piece, you never really said )

[Wurtsmith Vet]

Very tough luck. Been there, done that. At least the easy part will be removing the remaining stud. Hard part may be finding a replacement bolt as most jobbers won't just sell you one, but having a few back-ups on hand is never a bad deal. Good rule of thumb that has served me well in the past is anything under 25HP- use 3/8" or smaller. Ford and tractor use- 1/2" and above. Of course, if you own a Honda- hammer and dull chisel will suffice for most overhauls! Old Sarge.

[johnny6speed]

Nope its still in there. Dropping it off at my awesome local Yamaha dealer (Woody's in Topsham, Maine). Gonna let em handle it. I am too frustrated with my ignorance at the moment to attempt removal of it.

[grayracer513]

Hard part may be finding a replacement bolt as most jobbers won't just sell you one, ...

Hmm?

The bolt is packaged as a single part: PN 90159-06010-00, $2.00 at retail.

[Wurtsmith Vet]

Better Clutch than cylinder stud.

Edited September 27, 2011 by Wurtsmith Vet
Double post

[swaldrop]

New clutch boss is like $50 right? Seems like it would be cheaper just to get a new one than paying a shop to do it.

[grayracer513]

New clutch boss is like $50 right? Seems like it would be cheaper just to get a new one than paying a shop to do it.

Paying a shop to do what? That bolt will back straight out if you hit it with a left handed drill bit. The boss retails for $76, BTW.

[johnny6speed]

Yes, I am paying my local Yamaha dealer to back the bolt out. I loaded the bike up and dropped it off instantly due to frustration per my own ignorance. It may be perceived as ignorance for not going to my local hardware store and purchasing a left handed drill bit but, I was upset and pissed off, so I decided to let them handle it.

[DBMX 925]

Yes, I am paying my local Yamaha dealer to back the bolt out. I loaded the bike up and dropped it off instantly due to frustration per my own ignorance. It may be perceived as ignorance for not going to my local hardware store and purchasing a left handed drill bit but, I was upset and pissed off, so I decided to let them handle it.

AHHHHHH been there. Kinda like remodeling around the house.

[johnny6speed]

There is a happy ending to this story. The dealer was kind enough to back it out for me for minimal charge. We all had a good laugh at my ignorance and they all made me feel better explaining it happens all the time etcetc. But, after speaking with the owner of the dealership for a few minutes about why I broke it and what I was installing it created a buzz around the dealership. North of Boston Jr, (Portland Maine) the off-road motorcycle scene is limited to a few moto-x tracks and ADV riders on KLR type bikes. So once I set my freeplay gain in the parking lot, I asked the owner permission to ride on the abused grass on the property. He of course obliged and asked if he could try my bike with the EXP 2.0. After only a few minutes, he drove it directly into the shop, and motioned me over, asking me if everyone could try it. Of course I was excited too and let the gents that wrench on these things try it. Everyone in the dealership took it for a spin, never hearing of this "Rekluse" auto clutch. Everyone came back with a smile. I kept listening to their comments "this must be awesome in the woods", "it's seemed to tame the bark down a bit".. Overall per usual at Woody's a great dealership experience.

On to the clutch. I rode in the rain for a few hours on my property and surrounding area. It's far easier to do grassy powerslides as I feel as if I have more control. Next I was doing the tightest figure 8's in my driveway I could do. I felt like I was on a giant blue trials bike. During this s*** weather we are having up here, I ventured out to the atv/snowmobile trail out back. ATM, its wet, snotty, mossy, rocks and mud. I felt comfortable standing up, leaning my head over the numberplate and just tractoring along in 2nd. There is a lot of mental improvement here for me I believe, not having to worry about fanning the clutch so the bike doesn't flameout has allowed me to focus more on other things. This bike has now really become exactly what I wanted. Though I understand that becoming more comfortable with the clutch lever to the point where it is muscle memory and I don't have to think about it, is an important skill to have, but, for a bit of engineering and a few hundred bucks, its worth the "cheating" factor.