Is there anyway to make the 06-10 Rekluse fit my 04 TC450 ?

[Kam1]

I have the 7602 deeper clutch cover for the rekluse already the sight glass is awesome- however I put off buying the Rekluse until now and was just wondering if there is a way to retrofit Rekluse from newer model 06-10 to my 04 even if it means new clutch basket etc. Thanks in advance for any input.

 

[HoserX]

Subscribed.

 

[Colo moto]

I have the 7602 deeper clutch cover for the rekluse already the sight glass is awesome

Thanks for the kind words about our clutch cover. Have you tried doing a search here for rekluse fitment? It has been brought up several times as to what is involved in fitting one years clutch to another years bike. I know the info is on here somewhere, just can't seem to remember exactly where.

 

[sharpie1]

I bought a used Rekluse out of a '07 TXC450 and it dropped right in my '05 TE510 (with a 7602 clutch cover of course). If the Baskets are the same in the '04 and '05 it should fit. I have the identical Rekluses in both of my TE's, its the Z-start Pro model 856 I think, I actually think they quit making them???? But there are some out there and available online. I actually have an original Z-start (not the "pro") from my '05 I'll part with cheap...

 

[Kam1]

I am very interested in youre spare 05 Rekluse, I will pm you with my contact info. Thank you

 

[Soviet]

I have installed the Z start pro 856 (fits 06-10 450/510 and wr300) in my 04 TC450. The basket in the 04 is special. Its a one piece steel unit with the gear and basket milled from one piece. Regardless, anything 05 and newer is the riveted gear to an aluminum basket and that is a direct bolt in affair per instructions. You CAN make the 856 fit the 04. In order to do so I needed to remove the OEM spacer than fits between the factory basket and hub(it's likely 1/8" thick). I installed the rekluse hub without any spacer between the basket and hub. The rest of the hub installation is normal. I then had to use the widest throw out bearing shim and did NOT use the ball bearing under the throw out rod. It took me 10 tries of different spacing variations to get the clutch over ride to work as intended, but spacing was perfect. Didn't even need a larger clutch cover and the clutch worked as designed. If none of that makes sense, its because you don't have those parts in front of you. I would HIGHLY recommedn the Z start PRO over the older Z start. I tried both when trying to get the rekluse into my 04 and the Z start pro was infinitely better. Just my 2 cents.

 

[Kam1]

Thanks for the input, I will likely try the used one sharpie has if price is right, then if I like that I will upgrade to the pro, can you just switch clutch basket to the newer style?

 

[Xcuvator]

I have installed the Z start pro 856 (fits 06-10 450/510 and wr300) in my 04 TC450. The basket in the 04 is special. Its a one piece steel unit with the gear and basket milled from one piece. Regardless, anything 05 and newer is the riveted gear to an aluminum basket and that is a direct bolt in affair per instructions. You CAN make the 856 fit the 04. In order to do so I needed to remove the OEM spacer than fits between the factory basket and hub(it's likely 1/8" thick). I installed the rekluse hub without any spacer between the basket and hub. The rest of the hub installation is normal. I then had to use the widest throw out bearing shim and did NOT use the ball bearing under the throw out rod. It took me 10 tries of different spacing variations to get the clutch over ride to work as intended, but spacing was perfect. Didn't even need a larger clutch cover and the clutch worked as designed. If none of that makes sense, its because you don't have those parts in front of you. I would HIGHLY recommedn the Z start PRO over the older Z start. I tried both when trying to get the rekluse into my 04 and the Z start pro was infinitely better. Just my 2 cents.

I'm trying to figure out why that works on the 05, because the plates and basket are different, according to the research I have done .
I have to believe you, just can't figure it out.
Several years ago I did some testing for Alan at RevLoc when he was trying to develop a DynaRing for the 05 450/510. The unit he sent out had lazer cut steels (thinner) that didn't work out because they would warp and make setup impossible. He searched for other plates, but because the 05 TE was the only one using what they do he couldn't find what he needed and abandoned the effort. From what I remember pre 04 used the same and 06 to present use the same plates and are of a different diameter than the one year only 05.
Where am I off here?
BTW, have you noticed any wear issues because you don't use a ball bearing on the end of the push rod?

 

[Soviet]

Thanks for the input, I will likely try the used one sharpie has if price is right, then if I like that I will upgrade to the pro, can you just switch clutch basket to the newer style?

No. The entire set-up is different. I actually tried getting that Z start to work in my 04 even though it was apparently designed for the year and make, and i could never get it to work properly. In my opinion it was a poor design. Dan at MotoXotica also said that when I mentioned what I was doing. The Z start pro is the cats meow and a very good design. Uber bullet proof and it works perfectly.

I'm trying to figure out why that works on the 05, because the plates and basket are different, according to the research I have done .
I have to believe you, just can't figure it out.
Several years ago I did some testing for Alan at RevLoc when he was trying to develop a DynaRing for the 05 450/510. The unit he sent out had lazer cut steels (thinner) that didn't work out because they would warp and make setup impossible. He searched for other plates, but because the 05 TE was the only one using what they do he couldn't find what he needed and abandoned the effort. From what I remember pre 04 used the same and 06 to present use the same plates and are of a different diameter than the one year only 05.
Where am I off here?

04-10 use the exact same drive and friction plates. I did a ton of research before trying to figure out if I could make the 856 Z start Pro work in my o4. I talked with some doods all over, and in short, the drive plates and friction discs are identical throughout the years 04-10. So, I first thought that I was going to have to swap out the basket from a newer bike. The problem with that is the newer bikes (05+) use different crank/basket gearing. Normally you could just swap out the gear and use the newer basket, however because the 04 uses a one piece basket, that isn't an option. I thought it was gonna be a massive headache. I started deducing that if the 04 uses the very same design and amount (8) of frictions/drive plates as the 06-10 models, why wouldn't the assembly work if the spacing could be corrected? The hub was the easiest part. it fit perfectly IF i removed the OEM spacer that resides between the hub and basket. Then came the trial and error for getting the clutch over ride to work. Because I was using the system in a difference configuration, I needed to compensate for that. In the end, I didn't use the ball bearing like in their instructions under thier throwout bearing sleeve and used the thickest throwout shim they offered. The actual automatic clutch engagement I left at thier recommended settings, which was medium/hard (can be adjusted to peoples specs with included springs).

 

[Xcuvator]

04-10 use the exact same drive and friction plates. I did a ton of research before trying to figure out if I could make the 856 Z start Pro work in my o4. I talked with some doods all over, and in short, the drive plates and friction discs are identical throughout the years 04-10. So, I first thought that I was going to have to swap out the basket from a newer bike. The problem with that is the newer bikes (05+) use different crank/basket gearing. Normally you could just swap out the gear and use the newer basket, however because the 04 uses a one piece basket, that isn't an option. I thought it was gonna be a massive headache. I started deducing that if the 04 uses the very same design and amount (8) of frictions/drive plates as the 06-10 models, why wouldn't the assembly work if the spacing could be corrected? The hub was the easiest part. it fit perfectly IF i removed the OEM spacer that resides between the hub and basket. Then came the trial and error for getting the clutch over ride to work. Because I was using the system in a difference configuration, I needed to compensate for that. In the end, I didn't use the ball bearing like in their instructions under thier throwout bearing sleeve and used the thickest throwout shim they offered. The actual automatic clutch engagement I left at thier recommended settings, which was medium/hard (can be adjusted to peoples specs with included springs).

Good info- I should have verified some of the "facts".
It seems like Rekluse has had better things to do than adapt their clutches to work on all Husky models they could.
I was the second one, (that I know of) that put a RMS856 in a TE610
Thanks.

 

[Soviet]

Good info- I should have verified some of the "facts".
It seems like Rekluse has had better things to do than adapt their clutches to work on all Husky models they could.
I was the second one, (that I know of) that put a RMS856 in a TE610
Thanks.

No worries. I agree with you though. Rekluse didn't do much homework for applications. It fit in my 05 TE510 I bougtht 3 weeks ago without modifying a single thing from thier directions. Imagine that. The set-up was identical in every way to the 06-10 models. They should have put 05-10 in their applications. Strange.

Congrats on the 610 install. We gotta get what we want with what we got. Get creative or spend a lot of money I opt for the first route.

 

[Xcuvator]

No worries. I agree with you though. Rekluse didn't do much homework for applications. It fit in my 05 TE510 I bougtht 3 weeks ago without modifying a single thing from thier directions. Imagine that. The set-up was identical in every way to the 06-10 models. They should have put 05-10 in their applications. Strange.

Congrats on the 610 install. We gotta get what we want with what we got. Get creative or spend a lot of money I opt for the first route.

The 05 TEs, are good bikes, still have the 45 Zokes, but put some Riders Edge base valves and stacks will fix them. Just one of the neat things about them is that they still have the counter balance shaft. Mine runs like a top and I don't know why I check the valves cuz they haven't moved.

 

[rancher1]

Nice Bike, I really liked my 2005 because it was smoother than the later models and for some reason they seem to have the best durability ( maybe due to the counter balancer). I think rekluse doesn't include the 2005 model on the listings for the clutch is the different primary gear ratios.