Rekluse Auto Clutch in KX500

Burle
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Rekluse Auto Clutch in KX500

Post by Burle » Mon Jul 16, 2018 6:34 am

I think I've found a way to put an auto clutch in a KX500 without doing the 2 piece clutch cover mod. The bike I've got it in is a snowbike and as it's July I won't be able to test the idea for a few months. I'm not claiming this will work for sure as I have no experience with Rekluse's exp disc so any input on problems I may encounter would be greatly appreciated. Bear with me as I have no idea how to make a post like this and the pictures and chronology may be screwy.
As far as I know there is a known way to make the zstart from a DRZ400 along with the stock clutch pack and a 2 piece clutch cover work. I recently saw that Rekluse makes a torqdrive clutch pack, which is essentially really thin drive and friction plates. I thought if they turned out to be thin enough the 2 piece mod might not be necessary. Through research I found that a '08 KX450's clutch plates are the same as a KX500's. I ordered Rekluse's radius x for a '08 KX450, which is the torqdrive clutch pack as well as the exp 3.0 disc.
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This is the stock clutch pack beside the torqdrive clutch pack


Stock clutch pack width is 33.9mm and the torqdrive clutch pack is 23.56mm. Looking good :D

Only problem I faced was that there was no gap between the clutch plates when all the plates and exp disc were installed, so what I did was simply put a washer between the little cap that the push rod pushes on and the pressure plate, that was the only thing I had to do.
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Push rod cap with stock washer


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Push rod cap with stock washer and added washer


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All installed



I put some grease on the heads of the pressure plate bolts and put the clutch cover on then removed it and checked the inside for grease, there was none, so I know they aren't touching, how much of a gap there is I don't know.

Another problem I encountered was that the radius x kit only came with 5 pressure plate springs whereas the KX500 uses 6, I'll have to see if I can order another one from Rekluse. I don't think it would be a good idea to use the stock springs as they are not designed to work with an auto clutch.

Let me know what you think, thanks

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Re: Rekluse Auto Clutch in KX500

Post by Sandblaster » Mon Jul 16, 2018 2:52 pm

Nice.
There has been rumors of guys doing it for years... except with the two piece clutch cover..
Then about a year ago I heard Rekluse was working on making one for the KX500.
Since then I have heard a lot of discussion on it but still have not seen anything from Rekluse.

Here is my thoughts on it..
The KX500 is basically using a clutch the size of a KX250 :shock:
I feel that they are barely able to handle stock power numbers.
Anything beyond about 65 hp the rear wheel will require heavier springs, more plates or something, or they will slip.

Jeff Grawbarger is burning up a clutch pack in just a few races on his drag KX500...
Of course his HP numbers are a bit above 65 RWHP :lol:

Soooo... I guess it depends on what your engine will put out and how you ride...
Keep us up to date on how this is working out for you.
Anything I hear I will pass on here...
If bikes are for kids I'll never grow up.

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Re: Rekluse Auto Clutch in KX500

Post by Sandblaster » Mon Jul 16, 2018 3:06 pm

Apparently, Rekluse makes what is called the Torque drive clutch plates that will allow you to use one more steel plate and one more friction plate...
I'd look into that... Alex Ward tuned me into that...

https://rekluse.com/product/core-manual ... ve-clutch/
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Burle
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Re: Rekluse Auto Clutch in KX500

Post by Burle » Mon Jul 16, 2018 5:21 pm

Rekluse probably gave up on it because KX500's make too much powah!!

Engine is pretty much stock, got FMF gnarly pipe

That link is for their torqdrive manual, which isn't an auto clutch, so because they don't have the exp disc in there they can fit more friction and drive discs as far as I know

About the clutch wearing out quickly, I have a friend who's ridden a CR500 for over 15 years and he used to have problems with overheating and clutches not lasting (woods/trails riding - heavy clutch use). He put in a zstart rekluse and due to the more perfect clutch engagement has much less problems with overheating or burning out clutch packs. Now that is on a dirt bike where the tire is able to spin, on my snowbike the engine will be working much harder as the track has ubers more traction. Also the zstart provides more clamping force than the exp disc. Many variables, I guess only time will tell when the snow comes around

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Re: Rekluse Auto Clutch in KX500

Post by Sandblaster » Mon Jul 16, 2018 8:06 pm

Cool..
Keep us updates 8-)
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Burle
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Re: Rekluse Auto Clutch in KX500

Post by Burle » Sat Aug 25, 2018 4:12 pm

Well I threw the wheel back on the forks and took er for a short rip in the woods. Rekluse performed perfectly, the bike just overheated quickly because of all the drag the track creates and you ride at WOT a lot
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Re: Rekluse Auto Clutch in KX500

Post by Sandblaster » Sat Aug 25, 2018 4:42 pm

Wow!
Good to know on the clutch...

What was the air temp when overheating?
What coolant were you running?
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Burle
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Re: Rekluse Auto Clutch in KX500

Post by Burle » Sat Aug 25, 2018 5:27 pm

Air temp would have been around 30 C (86 F), coolant temp got up to 221 F
I think the coolant I got from work which they use on big stationary Cummins, if I recall correctly the brand is Fleetguard

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Re: Rekluse Auto Clutch in KX500

Post by Sandblaster » Sat Aug 25, 2018 7:44 pm

Hmmm...
Warm temps for a snow bike to be ran in but that's a good test.
220 isn't all that hot... I've seen mine in the desert on 100+ days get a bit above that.
I don't know a thing about that coolant be we tested several coolants several years ago and the hands down winner was Royal Purple, Purple Ice.
It ran 20-25 deg F cooler then anything else we tried... Evans, Water Wetter, Straight water, 50/50 green stuff :-), Engine Ice, and many many more.
It might be worth a try.
If bikes are for kids I'll never grow up.

Burle
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Joined: Thu Oct 20, 2016 9:47 am

Re: Rekluse Auto Clutch in KX500

Post by Burle » Sun Aug 26, 2018 2:59 am

Thanks for the coolant info, I have heard of some guys running a tunnel cooler and I'd rather not have to do that. I'll have to find some royal purple, that's what I run for my mixing oil.

Agreed 220 isn't that hot but I have a carb heater (routes the bypass from the thermostat around the carb) and it was boiling the fuel in the bowl, so I shut er down. Coolant never boiled out of the overflow.

Riding it for half an hour isn't as full a test as I'd like to do on the clutch but giving WOT on a 500 and then after I pulled the trans oil filler cap and smelled for clutch and didn't smell any, so it's at least promising about this rekluse setup

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