Rekluse Pro install - think I got a bubble

Hey guys,

Just put in my Rekluse Pro on my '09 TE510. The auto portion of the clutch is working like a dream but the override feature (Pro) is not working. After talking with Rekluse and going over the install we think I have an air bubble in the clutch system.

I've bled in out multiple times, even borrowed a buddy's EZE bleeder that lets you bleed for the bottom up. I still cannot get the clutch to overcome the force of the wave springs and budge the pressure plate. Now with the wave springs out it will pump up and move the plate. Put the wave springs back in and nothing. It just works up and back down...won't pump it way to the pressure plate.

Has anyone else experienced this or have any tips to getting trapped air out of the system? Thanks for any help. I've spent entirely too much time on it today and am growing frustrated.

Lee

I think your gap is to tight. Did you use the feelers 180* apart from each other at the same time to check your gap?

I've pulled the slave cylinder out and looked at it. The bike is brand new but heck who knows. Like I mentioned with the wave springs out it will throw out the pressure plate but when I add the springs and put the plate back on....nothing.

Did you ever get anything resolved?

We just bought and installed a Rekluse Pro in a TXC 450 with the same problem. We called Rekluse and they gave the same answer about bleeding the line, but that didn't make a difference. My husband and his friend found that putting a 1.5mm washer in behind the cap allowed the clutch to override. However, the clutch lever now has no resistance when pulled in unless the bike is moving. My KTM with Rekluse has normal lever feel at all times. I'd really like to find a better solution than the washer, though. It worries me that the clutch is "rigged" to work...is there danger? Will it cause clutch damage? I also feel a little ripped off!! So, husky123, did you find a solution for your 510?

It ended up being the wrong wave spring for me. Rekluse accidently sent me the tuning instructions for the WR250 and I didn't notice at first. It called for the taller wave spring and what was happening was basically coil bind. The wave was so bound up it would just push the pressure plate right back. Once I put the right wave spring in (can't remember which one) it was good to go. Override worked like a champ.

Cool I am glad you got it working properly.

Thanks husky123. I didn't realize my husband had sent a message to you on Thumpertalk. I'll look into that and any other parts that may be missing.

Overall I like using the Rekluse products, but their quality control for packing stuff up properly is suspicious. On a previous install they had the drive plates labelled backwards, which messed up my install there until I actually measured them and discovered their error. Their support has been awesome for me though, in that case they sent me out an entire new clutch package and just asked that I ship the other one back. They paid for all the shipping.

Well it looks like that was most of the problem. We had a WR250 setup sheet in the box. I looked up the correct sheet on their website and most of the problem was solved. The clutch now disengages when the lever is pulled.

However, the floppy lever problem remains. Compared to the way the clutch lever used to feel when pulled, it seems downright floppy. When sitting off or idling, it flops right back to the lever with no resistance. When the throttle is pulled, the lever regains some feel, but not anywhere like it was before. Does anyone else have this problem? My KTM feels normal, which makes me suspicious.

Phoenix,

I think what you are describing is how mine is, virtually no pressure at idle, hardly any when revved up, but it still fully disengages.

It will be MUCH softer. I don't know if I'd classify it as floppy. Remember once the Rekluse is installed it is just pushing against those two little wave springs for resistance not the 6 big honkers that come stock. It's basically a pinky clutch after the Pro goes in.

Okie dokie. It sounds like this is normal for the Husky, so i'll quit worrying about it. Thanks everyone!