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Old 12-28-2011, 01:27 AM   #16
crashmaster
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I've been running the z-start pro on my 990 for about 50,000 miles. I absolutely love it. Might even put one on my 450, but then all my buddies would call me a pansy. But they can do that all day long as they watch me climb up boulder fields meant for a trials bike.
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Old 12-28-2011, 05:58 AM   #17
Pete640
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I can see an exp in the 950 in the near future. Old clutch is getting very tired and the benefits of the exp and eng braking sell it for me. New frictions/steels and maybe an updated basket will see it another step forward. (Not too many steps to go....)
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Old 01-04-2012, 09:00 AM   #18
cjracer
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REPORT BY: craig (CJRACER)

LC8 Rekluse EXP update after ~ 7,000 miles.

I had the chance to TEST an early prototype version of this clutch starting Sept 2011. I had over 60,000 miles on my earlier Z-Start PRO Rekluse and really like how much more enjoyable it makes my touring/ Off-road Dual sport riding/ and Racing. I was very interested in comparing these 2 systems, but had to keep my mouth shut on many details during that time.

Many think that installing a Rekluse will turn your bike into an Automatic transmission. This is wrong. You still need to shift gears at the appropriate time, but this will slip/engage the clutch better and more consistant than a normal human can do all day long. Riding a 550lb bike offroad has it's own challenges. Having a Rekluse in my Adventure makes it feel like it's lost 100 lbs. I can consentrate on line choice and balance and keeps my arms from pumping up after a long day of trail riding. Off Road it makes for easeir starts on hills, in mud and sand, b/c you can easily control wheel spin.

ON road I enjoy it b/c it allows for a more relaxed ride around town and stop and go traffic on the freeway is a breeze. Put it in 1st or 2nd and just roll on and off the trottle. You have enough to keep an eye in rush hour traffic (Cell phone users and Texters), A Rekluse can help get rid of another added stress.

I feel that this NEW EXP system has much better and more consistant on/off throttle conntrol. Engine braking is still there down the engagement point setup by the installer. Many options are possible by changing out differant stiffnesses of spings and ramp weights.

I started with a setup that felt more like a MX bike. It would shift out hard and at a higher RPM (~1800RPM) Then changed to a softer setting that felt much more natural. This would start a smooth engage around 1,500 PRM and be fully locked in around 2,300 RPM. We did this testing on a Dyno and could see this in the torque curve.


In order to install the NEW EXP on my bike I was required to reinstall all the stock clutch parts (Center hub- booster system) This was only b/c I had the Z- Start Pro system installed

This NEW will allow for faster and easier installs for EXP Rekluse purchases.

Another Great plus of this system is that it comes w/ a NEW clutch slave that allows you to lock out the system to potentially bump start the bike.

This is built in to the NEW SLAVE unit.


I started by removing my Oberon Slave unit and installing the REKLUSE Slave. There is an EXTERNAL adjustment system on the LC8 EXP. You can fine tune the Clutch Gain and lock it out for bump starting w/ only a 13mm wrench and 4 mm allen. This is differant than the Z- start Pro. The PRO system required you to take the end roller system off the assembly and replace a steel shim w/ a thicker one. This system is much faster and easier and can be done trail side.

While you're in that area check your OIL JET for anything plugging it.

(I drilled mine out to .5mm to increase oil flow to the system. This helps keep things cooler, potentially keep the just from clogging sooner and should prolong the life of the booster ramps.

One down fall is the bike might need a little blip of the throttle to get it in to nuetral when running. Shifts normal any other time. I normally coast to stop engine off and click to nuetral once stopped, that's my system)

Tighten this down and bleed out the system.

Next up was removing the clutch cover and pressure plate. Pretty straight forward. This can all be done with tools in your kit.

I removed the first fiber and steel plate. Set those aside w/ the pressure plate. The first fiber against the ALUM pressure plate is a special KTM fiber.

Them remove the next 3 fibers and 2 steels.

The EXP Core is held together by 6 small clips. In between them are the weights and spings. The entire Assembled core replaces 3 fibers and 2 steels.





The pressure plate only fits in one way. Look for the arrow on the face and match that up w/ the arrow on the center hub.

Bolt everything back together like a normal clutch. Clean out the threads of the booster studs and install some blue loc-tite to make sure this won't loosen up.



One great thing w/ this new system is there are NO BALLS to deal w/ and it can easily be installed w/ the bike on it's sidestand w/ almost NO oil loss.

My EST would be to figure about 3 hrs for your average wrench to install this. If you've already worked on any of these systems it should be about 2hrs.

Bolted the clutch cover back on.


Started it up and adjusted the clutch save for the proper Lever Gain.

The z-start PRO system had the required GAP built into the system Internally by replacing steel shims.

The LC8 EXP system has the GAP set Externally by the SLAVE and the adjustable piston and jam nut.

Break the system in w/ some slow starts and stops per Rekluse instructions.

If you want to change setups on the CORE, I start by removing tension on the SLAVE adjuster. Them remove the CORE like you would replace a fiber. Much faster than the Z-start Pro.


I did all this the weekend before I left for the KTM National Rally in Lake Tahoe, NV 2011. A few test laps around my track and subdivision. I was comfortable and confident in the system.

I packed up the bike and headed west. Let the TESTING BEGIN:
And as in normal CJ testing..... this won't be your average ride around the block.

When heading WEST from Wisconsin the first challenge is getting accross the plains. This would LONG sustained speeds for hours on end and often 200+ miles between stops.
After a day and half and over 1,000 miles across the plains it was great to be off the freeway and camping. Next day would be more dirt testing.


The system worked great. No issues, on/ off throttle was smooth and consistant. Engine breaking was normal and was tested on every off ramp.

Next day was down through WY into northern CO and into UT. About 600 miles camping in the sand dunes West of SLC, UT.

Again, no issuues. Clutch gain and engagement felt the same all day long.

I arrived in Lake Tahoe, NV ready to hang out and hit some trails.

More to come......
http://www.advrider.com/forums/showthread.php?t=753701
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Old 01-04-2012, 12:02 PM   #19
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Old 01-04-2012, 04:28 PM   #20
sledstorm1
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Quote:
Originally Posted by xcflyn View Post
re-hashing a dying thread here

Hope this is good information- takes me a freaking hour to type this much .
I love Rekluse clutches, (3) Soon the 990...Thanx for taking the time to share some usefull info!
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Old 01-05-2012, 02:59 AM   #21
emuooz
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Mines ordered through blackdogs can't wait !!!

Kurt I would appreciate a heads up when your going to start shipping them

Cheers Jeff .
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Old 01-05-2012, 03:11 AM   #22
Pete640
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Great write ups guys. Just one question tho - whats the difference between the EXP and the "CoreExp Clutch Kit" as being pre offered by KTMTWINS? Is it the external adjustment slave as I cant seem to pick any other obvious differences?
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Old 01-05-2012, 05:41 AM   #23
cjracer
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Quote:
Originally Posted by Pete640 View Post
Great write ups guys. Just one question tho - whats the difference between the EXP and the "CoreExp Clutch Kit" as being pre offered by KTMTWINS? Is it the external adjustment slave as I cant seem to pick any other obvious differences?

It's the same basic thing.

There is only 1 EXP system available for the KTM 950/990. The pic shown on KTM Twins is not the KTM LC8 kit. The KTM LC8 kit will include the NEW Rekluse slave unit. The other CORE EXP kits have an adjuster on the Pressure plate.

BOTH use the NEW 2.0 disk system.

The CORE systems often have more parts included. (Clutch cover, center hub, steels, what ever is required for that bike)
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Old 01-05-2012, 07:16 AM   #24
Pete640
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Thanks Craig I look forward to being exp equipt
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Old 01-11-2012, 02:25 PM   #25
kingoftwins
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KTMTwins.com Rekluse Picture Confusion

Hey guys. The picture on the Twins site was the base picture used on Rekluse's site for a bit but just now noticed that they have taken it down for confusion's sake I suppose. We will get more info on that kit as well as a updated picture or pictures when it finally gets released and we can get our dirty little hands on a kit. Looking forward to getting that in one of the LC8's here and taking it out to the hills in Northern Cali.

Quote:
Originally Posted by cjracer View Post
It's the same basic thing.

There is only 1 EXP system available for the KTM 950/990. The pic shown on KTM Twins is not the KTM LC8 kit. The KTM LC8 kit will include the NEW Rekluse slave unit. The other CORE EXP kits have an adjuster on the Pressure plate.

BOTH use the NEW 2.0 disk system.

The CORE systems often have more parts included. (Clutch cover, center hub, steels, what ever is required for that bike)
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Old 02-05-2012, 06:13 PM   #26
KTMforget
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Rekluse EXP install on 990 ADV

Hi Guys (and Gals)

Rekluse asked us to test fit the new EXP auto-clutch on our KTM 990 Adventure. Already having a z-Start Pro on my Super Enduro, I was anxious to see the new design. I admittedly did not install the z-Start Pro in my 950SE, as I simply ran out of time before leaving for a trip and my local shop has installed hundreds of them, so I dropped it off knowing it was in good hands.

Onto this install - most of which was performed my Mrs Black Dog (it is HER bike afterall...)

The new EXP clutch promised to be very simple to install with an external adjuster built into the provided clutch slave cylinder. As I understand it, there are several significant advantages of the new EXP clutch as compared to the z-Start Pro:
1. Ease of installation
2. Ease of adjustment – both with external adjustment of the clutch plates and engagement adjustment of EXP disc using provided springs.
3. Improved feel of the clutch
4. Ability to quickly adjust clutch using external adjuster to allow for bump starting
5. Ability to quickly adjust clutch using external adjuster to allow for standard manual clutch
6. Less expensive purchase price
7. Inclusion of clutch slave cylinder, saving $180 on aftermarket replacement.


Before beginning installation, we confirmed we had the correct type of mineral oil on hand for the clutch fluid.

Step one is soaking the EXP disk assembly in engine oil for at least 5 minutes.

Installation began with putting the bike on the lift and securing it on the side stand with additional tie down straps to hold it in place. Placing an oil pan beneath the clutch cover took care of the small amount of oil that dripped out of the bike during installation.



The top two clutch plates are reused, while the next five are replaced with the EXP disk assembly. Inserting the EXP disk assembly, and the top friction and drive plate, then installing the clutch cover, ensuring the gasket was in good shape only took a few minutes.





Next came the replacement of the stock clutch slave cylinder with the Rekluse unit. The spacer needs to be moved from the stock unit to the Rekluse unit. It is pretty much a straight swap over – just be sure to clean the area around the stock unit before removing it to be sure no debris gets introduced to the system.




The Rekluse product even includes a large syringe and tube to make bleeding the clutch easier.



One of the black dogs supervising




Be sure to check the engine oil level. We found that break in was critical in getting the clutch to work properly. A bit tough to do given the 15 feet of garage space I had to work with. Our initial test did determine that we needed to swap out 3 of the red springs in the EXP disk assembly with the blue springs, to provide a higher engagement setting. This is a 15 minute job thanks to the very slick design of the spring assembly.

Overall the instructions were excellent. We found a few minor corrections and improvements to suggest to Rekluse before they were published for consumers.

Giving the break in procedure some more thought, I backed the bike onto the ice in our driveway, where I could smoothly rev the bike up to 5000 RPMs the number of recommended times to break in the clutch. The chatter went away quickly and we were left with an auto clutch that engaged very smoothly and consistently, while maintaining excellent clutch feel. (Sorry, no photos of burn outs on the ice...)

All back assembled and ready to go...





If the weather holds up I may try to trailer the bike to town where the streets are clear to take it for a proper test ride, but all indications are that the EXP system is an improvement over the z-Start Pro with numerous beneficial features. I am guessing I will be swapping out the z-Start in my Super Enduro for one of these units as soon as the production models become available.

If you are interested in pre-ordering an EXP auto clutch for your 950 or 990, you can do so here:

http://www.blackdogadvbikes.com/blac.../275-2095.html

I hope that helps. If anyone has questions, please let me know.

Thanks for your continued support
Kurt
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Old 02-06-2012, 04:29 AM   #27
Dirty Dharma Bum
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Cool post, thanks Kurt

So now that Martha is the resident Rekluse installation expert can you haver her put one in the SE for me?
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Old 02-06-2012, 06:17 AM   #28
KTMforget
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Quote:
Originally Posted by Dirty Dharma Bum View Post
So now that Martha is the resident Rekluse installation expert can you haver her put one in the SE for me?
I don't think you can afford her...
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Old 02-13-2012, 03:34 PM   #29
cjracer
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If you enjoy traveling down that gravel road or giving it your all on some of the hardest trails around, the Rekluse EXP can be you "Secret Weapon" when it comes to smooth and consistant clutch control.


Pic by john beck


Boulder strewn slides like this become much more manageable when you worry less about miss-using the clutch and going over the edge.


See new sights that only smaller bikes could get to before.


We just got finished putting the final tests in on the 990 units and they should be ready to start shipping soon. I've got over 7,000 miles on there slave unit and it's a perfect match for this system.



Don't let that next unknown stop you. GO Explore!


Not only have a I tested it in some of the roughest terrain, but also some of the worst places you would ever want to be stranded.
Lonliest Road in the US. HWY 50 Nevada.





Now go find some dirt....
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Old 02-13-2012, 06:27 PM   #30
Pete640
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Well that sold it for me CJ - its on backorder. Any idea when the units will begin shipping?
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