KDX 200 Rekluse

[clint.melick]

I'm going to be putting an auto clutch in my bike. Here is the recipe i'll be following -
1994-2004 YZ 125 clutch basket – billet version $120 used

2004-2009 CRF250R clutch friction plates and steels. $54

Modified KDX drive gear

Stock KDX hub and push plate

Custom clutch pusher rod

Rekluse EXP auto-clutch - YZ125

http://haroldbawlzangya.com/project-kdx-rekluse-exp/" onclick="window.open(this.href);return false;

[clint.melick]

Here's the Hinsen basket with the YZ gear removed and the CRF250R clutch kit.

20140908_193353.jpg (1.4 MiB) Viewed 9939 times

The YZ gear is on the far left, and the KDX gear is the one on the right. The KDX gear will need to be machined to get the hinsen basket to fit flush.

20140908_193302.jpg (1.27 MiB) Viewed 9939 times

[clint.melick]

The hinsen basket also might need to be machined to allow clearance for the water pump gear. The pictures bellow are the stock basket.

[clint.melick]

Got the KDX gear machined so it can fit on the hinsen basket.

[clint.melick]

I got the clutch plates and the rekluse put in. It's in the bike and is working well.

Clutch basket used off ebay $120
Used KDX gear and basket (not needed if you use your own gear) - $56
Tusk CRF250 clutch set - $55
Machine cost for KDX gear $40
Rekluse - $still owe

So far $271

[clint.melick]

So after riding for a day I took it apart to see what the basket looked like, I wondered if the water pump gear would grind at the basket, and it did. Not too big a deal. I'll just change the oil to make sure any aluminum bits are out.

[clint.melick]

I ended up not using a custom push rod for the clutch, I just used a thick washer.