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It has been a long time in the works, but scroll down this page to find how to add a Rekluse EXP to an H series KDX.


KDX Rekluse EXP

Great info and great work. Sucks that it takes a few special steps that the average Joe isn't going to be able to due themselves.

I installed the YZ125 Rekluse 3.0 in my KDX200 using the Barnett basket per Ted's directions and it works just like it was designed for the KDX200. I used the Rekluse silver springs and heavy wedges to get the early & hard lockup for which I was looking. If you don't perform the last step in Ted's instructions (machining the bottom of the hub and installing the EXP in the middle of the pack with steels on each side of the EXP) the clutch will slip more and REALLY dirty the oil with aluminum stuff (I don't know exactly what is in the dirty oil but it is caused by the Rekluse friction material sliding on the hub flange). BTW, it looks like using the Hinson basket would be a piece of cake. I did not need to machine a new push rod using the Barnett basket. You can see my YZ125 clutch basket modifications here (I forgot to take picures of the hub mods but they look like Ted's but not nearly as pretty):
http://s34.photobucket.com/user/ken-pow ... ent&page=1

I am SO impressed that Ted managed to figure this out - Thank you Ted more than you can believe!!!

How much was machined off? Any measurements?

JasonK94Z wrote:How much was machined off? Any measurements?

I had the bike on it's side right there with me when I machined the basket. I took a little off at a time until the water pump gear cleared the basket. I took off a lot more than I thought it would take! I think Ted did the machining the same way that I did it. Sorry I don't have a measurement that you can give the machine shop.

To add to something Ken said, the differences between the Hinson and Barnett baskets are more significant than I expected. The diameter of the Barnett at the base of the clutch fingers is maybe 1-2mm larger than the Hinson. So more aluminum needs to be removed to get the same clearance as the Hinson would require.

And the inside of the Barnett is substantially different that you can't just drop the rest of the KDX clutch in and go riding like you can with the Hinson.

The Barnett has the cool factor with the stainless inserts, but the reality is that a billet basket with the EXP handling the slipping will probably last a very, very long time before it would get notched.

The Hinson baskets are easier to find and require the least amount of work to get them going.

SS109 wrote:Great info and great work. Sucks that it takes a few special steps that the average Joe isn't going to be able to due themselves.

Indeed!;)

And I'm below average Joe.

I believe EFM Autoclutch still makes one for a KDX200. Yes, at first mine slipped but after talking with Gary Buzzelli and discovering the six screws with spacers at the bottom of the clutch basket it's been an excellent auto clutch. I also have two RevLoc clutches that work very well in all conditions. BUT Best of all is moving your rear foot brake to the left handle bar. The auto clutch/ left handle bar rear brake has really improved my riding! Occasionally I see auto-clutches for KDX200 on Ebay....

Roughly...How much is an auto clutch left rear brake set up going to cost me for my 2002 Kdx 200 ?

EFM or Revloc...
I'm seriously thinking of it for 2015 :)

Efm is $700 I did my lhrb for less then $100.

oh man, hadn't thought of having a left hand rear brake, that would be fantastic in tight woods.

also, it would hold the bike on hill climbs if the bike was stalled, and allow for easier standing in tough terrain, and shifting, and and and



ok, I gotta do this now.

royadams wrote:I did my lhrb for less then $100.

What is your set-up?

Tedh98 wrote:

royadams wrote:I did my lhrb for less then $100.

What is your set-up?

I bought a hayes stroker carbon mountain bike master on ebay for around $50, thats what the recluse uses. A line kit with bonjo fittings$20. I say this because i first ordered the wrong line. And had a friend machine me a fitting to replace the reservoir in the rear brake master.
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This is awesome and not to out of the way to do. Which would be a better unit to use? yz125 rekluse exp or crf250 exp?

factoryX wrote:Which would be a better unit to use? yz125 rekluse exp or crf250 exp?

Those could be identical. The EXP halves are the same, but the CRF could come with a different combination of engagement springs. It might come with heavy wedges, but I doubt it.

Excellent work guys - this should be a sticky!

Did you use six silver springs and still need heavy wedges???

You still doing these, Ted?

royadams wrote:

Tedh98 wrote:

royadams wrote:I did my lhrb for less then $100.

What is your set-up?

I bought a hayes stroker carbon mountain bike master on ebay for around $50, thats what the recluse uses. A line kit with bonjo fittings$20. I say this because i first ordered the wrong line. And had a friend machine me a fitting to replace the reservoir in the rear brake master.
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that's pretty freaking nice !

Last weekend I tried out positions of the lever and think I've found something that works, basically a carbon copy of yours:




Now I just have to figure out how long of a brake line to order, fittings, drill and tap the stock master cylinder, and test it out without crashing :D

Do you have anymore info you can give, pertaining to the steps I have left ?

Thanks !

I would like to thank Ted also. With out Ted having done it which proved it could be done I would never have done it myself.

If your a cheep scape like me it can be done with a YZ125 basket with all the same clearance problems.