250-500cc WR360 NOW WITH RECLUSE Z START PRO

I thought that it’d be wicked if I could put an auto clutch in my 2000 WR360 as the clutch pull was quite heavy & it would just top off such a great bike. I was warned against using the Recluse EXP as the torque of the 360 was too much for the EXP so after making enquires about the Relcuse Z Start Pro I was told that they would fit my bike, so I ordered one & went to install it. Unfortunately this was not the case, due to the 360 only having 7 clutch plates & the Recluse using 8 plates & the Recluses pressure plate not engaging the 360’s basket enough for my liking. As this model Recluse Z Start Pro (RMS-856) is good for other Huskies, the 360 project was shelved & it went into my 08 TE510 instead. Until now.



A friend had me install a 6 speed from another 360 into his 09 WR300 & while it was apart I tried the 300 basket in the 360 but soon realised the primary drive on the crank would need to be changed as well as the water pump gear & the power valve gear as well & that was getting in the too hard basket. The ring gear/clutch bearing of the 09 300 is one piece & the 360’s was 2 piece which wouldn’t allow it to be separated.


The primary drive of the 360 is 25/60 where the primary drive of the 250/300 is 27/69 & this is common for all of these models. This got me thinking that the only thing that we really needed was the 360 primary drive & a basket capable of holding 8 plates (250), that would fit into the 360 clutch housing & assemble them together. I happened to come across a 1999 WR250 clutch basket (Part No 8001 86863), which is a 2 piece ring gear/clutch bearing setup & in excellent condition & I thought it might be suitable, so I snapped it up hoping that the ring gears were able to be swapped out.



I first checked the Recluse in the 250 basket & all was good for the 8 plates & the height was good for the Clutch housing.



So I drilled out the rivets of both baskets


& was happy with what I saw





The ring gears were the same internal dimensions but just had different numbers of teeth.




I installed the 360 ring gear on the 250 basket, reinstalled the backing plate & riveted it all back together.


The shim that the clutch bearings sit on (No17 in exploded diagram) had to be replaced with a thinner shimming washer as the clutch basket spacer washer (No8) was touching the clutch basket & locking it up.


After replacing this shim (No17) the clutch was free of the spacer washer (No8). The rest of the Recluse went in as per the installation guidelines & the 360 throw out bearing was used together with the WR250 Recluse spacer.


The throw out had to have the screw turned in by about 4 mm for the extra clutch plate & steel & to allow the correct free play at the clutch lever on the bars.


When I went to install the clutch cover the casting for the sight glass was just touching the top of the Recluse top plate, so after grounding a bit out of it for clearance I realised it would be better to use a spacer plate.


I had some 2.5mm aluminium sheet lying around in the workshop, so I put a gasket on it, traced around it, cut it out & sandwiched it in between the cover & the housing with a gasket either side & it is barely noticeable.



I tried a few different spring/ball combinations before settling on what Recluse recommended for the WR250 2 Stroke – C200L5 & C150M3 with 24 steel balls & 3 Tungsten ones. This allows a hard engagement with medium revs, just the way I like it. For a bit smoother engagement I might remove the 3 Tungsten balls. Maybe

The clutch feel is super light, like my 125, when I have to use it & the 360 clutch basket rattle has gone. I couldn’t be happier with the big girl now. It has been a mission to get this project to where it is now but well worth it so I thought I'd share it with you all.

Awesome work Dude!

That's what I love about the WR engine platform, there are some many different parts combos from all the years that can be interchanged that you can do all sorts of neat stuff.

I'll bet that if you use the cover from a current 250 / 300 that you would have to make the spacer. Oh, and that spacer, awesome work there too. You are an artist.

Thanks for sharing.

Sweet !!

Thanks Motorhead I like to share this info with every one here. I did try the clutch cover from a 2010 300 and all but 2 bolt holes line up, unfortunately.
Does any one know if there is a billet option for the 360?

I'd guess it is fair to say you know clutches Great work and how does it feel riding that beast 360 with this clutch installed?

No clue on that billet question ...

Ausky...so when do l freight up my 360 basket for you

Just the ability to replace the clutch plates with Wr250/300 is a big bonus!!

Billet clutch cover are very hard to find for the 360's (l've tried) and the only option that l can find is someone to CNC one.

Very nice work!
People talk (complain) about how the 2 strokes never get updated, but there are advantages to sticking with a proven-good platform.

Awesome post great information. thanks

To be honest Ray Ray I havent had that much time on it. I have had to go away working.
The ride I took it on was great the clutch lever is ultra light & doesn't slip at all and feels really strong & positive.
Cant wait to finish my shift to give it a good ride!!

Hi OMG,
To do this mod you will needthe clutch basket from the WR250 1999+ part No 8001 86863
The clutch plates from the 510/450's will fit in there also, at least from my 08 510 probably other years as well
Let me know if you find the billet option mate, im keen, just needs to be 2.5-3mm deeper

Hi Xcuvator,
Its amazing what a great platform the Husky is, this combo works well

FBF has billet baskets for the WR250 and the 450 / 510's for about $200.

sorry to jak the thread but does this mean a 250 clutch basket is the same dimentions as the 360 just taller?
so if i get the talon 250 basket i can install it in my 360 with new rivits and putting 360 gears on?
oh and a spacer for the cover.?
awesome write up

incredible job, awesome man! that bike'll go anywhere now! barooop dadingdingdingding.

This will be an autumn project (as soon as l get my WR250 on the road) as the benefits of clutch plates availability warrants this mod IMO. When l get to it, l'll get a mate to quote up the cost of making a 360 billet cover @ 3mm deeper with the issue only being the sight glass which l'll have to source the equivalent unless l'm able to press out the original.

Great work, but I have to ask couldn't you just have installed the rekluse in the 360 basket with 7 plates?

The billet 4 stroke cover from bill's just has a threaded oil check hole with a bolt. The site glass is convenient, but since having had them break on 2 bikes now, I'd prefer the hole.

Yes Juicy.
The only difference is the height of the fingers on the basket & the ring gear, the rest is the same.
The billet basket would work if the damper rubbers had the same D shaped mount beneath the backing plate. Not having seen what it looks like I couldnt say for certain.

i ask cus talon dont stock a 360 basket, an im using bike so sending it off to get reproduced is a ball ache, thank you for quick responce and being so detailed

oh and do you know the logic of the smaller powered bike having an extra plate in? to me thats backwards.