125-200cc DNF & rekluse

I had my first DNF on the WB165. First one in 20 years (my KDX was bullet proof). My Rekluse started acting up on the first loop. Had some stalling problems so I turned up the idle and that helped some. Came back to gas and headed out for the 2nd loop and noticed it stalling a lot more. At the reset I tightened the cable to get more free play on the Rekluse. At a 1/2 mile in it would not disengage at all and the clutch lever had almost no resistance at all. I got back to the pits and loaded it up and called it a day. Got it apart today and found the Rekluse and plates looked great. Dug a little deeper and found the clutch push shaft and push rod had some issues. I had a hard time getting the rod out of the input shaft. Looks like it had some galling from the trany shaft.

Yours is the second one that I have seen do this with the recluse exp auto clutch pack. The good thing is that the transmission shaft is so hard that the galling that you see will not have done any real damage to the shaft. Probably worth cleaning up and definitely install a new clutch rod. The clutch actuation arm is toast as you obviously know and will need to be replaced. To make the auto work you have to adjust your clutch to have constant pressure against the rod, arm, cable, and at the lever. I think this causes the rod to be constantly spinning with pressure against the actuation arm. I think this is the root of the problem. Whether using different adjustment points or spacer sizes will help this, I have no idea. Most recluse exp users don't see this problem but you are not an isolated case. Consider yourself lucky that you did not break the arm, as you would then need to split the cases to get the pieces out.

PS, Unfortunately this is not a problem that is just 165 related. I think any of the tiddler 125's have the possibility of this happening. Maybe a possible solution is going to the older style rod assembly that has two rods and a ball bearing in between the two and at the throw out bearing.

how old does that part go back? My bike does have the 1 ball at the throw out bearing.
your right the 165 is still running great.
Would love to try my 165 with the WRE Counter Balancer in it. Guys that have not raced a bike with one are missing out. You don't see 4 strokes with out one. To bad GG drop it from their bikes.

It looks like they made the change after 07. So you can order the parts from any 125 pre-08. I would also make a point to keep your tranny oil very clean with frequent changes and probably running slightly over full so that you get plenty of clean lubrication to this area.