Rekluse z-Start Pro 101 Installing a Rekluse www.rekluse.com zStart Pro auto-clutch in my 2007 KTM990S! :eek1 Here are a few pictures of my recent installation of a very new Rekluse z-Start Pro for the big twin KTM (will work on any KTM 950/990 v-twin, SE, SM, SD). I did the work myself and this report is by no means a complete technical document, and is being supplied just for your curiosity. Accurate technical docs are supplied with the Rekluse kit and the KTM engine shop manual was my other reference. First, remove skidplate then place the bike on it's left side. I didn't drain any fluids and nothing leaked out of the bike even after a few hours sitting that way. I've done the canisterectomy and proper tank venting so no problems with fuel dripping. I put a few shop towels on the floor and put the bike on it’s crash guards and rear luggage rack, nothing else touched. Remove clutch cover Remove pressure plate screws and springs Remove friction plates and steel plates, paying particular attention to the last special metal friction plate and 2-part Belleville clutch boss spring – those will be going back in later per Rekluse instructions. Then remove the clutch nut remove the center hub Here is the clutch basket empty but still in place Note this spacer ring, do not remove it. Install the Rekluse center hub Rekluse says to use the stock washer and clutch nut to attach the hub but I didn’t think the nut threaded down far enough so I removed the washer and put the nut straight down on the steel hub with Blue Loctite. I didn’t see any problem with doing that. This was a very early kit and I’m sure Rekluse will address the issue with production kits. Next place the first Rekluse steel plate and then the re-used special thin steel plate (blue arrow) and inner 2-piece Belleville clutch boss spring (red arrow), detailed in Rekluse instructions. Then load the clutch pack per Rekluse instructions, steel, friction, steel friction, etc. Stock friction plates are re-used in this kit. After all the frictions and steel plates are inserted, install the Rekluse middle hub assembly. This supports the top pressure plate assembly. It’s important to make sure to install the thrust bearing correctly per Rekluse instructions Here it is installed. Next install the engagement RPM wave spring. Engagement RPM can be set using various strength springs here. Rekluse can supply various tension springs and provide a proper spring in the kit based on the average idle speed of the KTM 990/950 engine. The ball plate All loaded up with steel balls. A few tungsten balls can be substituted for firmer engagement action but I’ve been happy with just steel balls in a variety of riding conditions. And finally the top of the pressure plate is fastened down with 10 screws and Blue Loctite. All done with auto clutch assembly! There are a few steps to measure the pressure plate/friction gap for proper setting, and can be adjusted with several thickness steel plates Rekluse provides. The Rekluse instructions explain this procedure and I found it very easy to check and adjust. Remove middle rubber damper from the clutch cover plate since it will not fit with the new auto-clutch installed. Then put the cover back on and have fun! Oh, you will need to follow a very simple Rekluse break-in procedure that takes all of 30 minutes, cycling up and down through various RPM ranges. This is detailed in the Rekluse instructions. Rekluse inside! How does it work? Well, I just came back from a 3600 mile 9-day 5-state (WA, OR, ID, NV, CA) ride with it that ranged from cold mountain passes to blazing hot 6-bar days, Bonneville Salt Flats speed runs, Blackrock Desert playa running, long IronButt days at spirited highway speeds, part of the trip 2 up with full luggage on super-tight twisty mountain roads. Off-road on rough 2-track trails, whooped out roads with deep sand washes, silt beds, sharp rocks, steep rocky hill climbs and slide-downs. Did a little bit of everything except deep water crossings, mostly because I didn’t see any. The Western states are pretty dry right now. Ride report soon... The Rekluse auto-clutch performed flawlessly! In heavy stop and go traffic having an “automatic” is awesome. On rocky hillclimbs I just popped into 2nd and chugged my way up whatever was in the path. Never touched the clutch, this unit ‘feathers’ the clutch on gnarly terrain far better than I ever could. This is my second Rekluse zStart-Pro, the other is in my Aprilia RXV550. So far I haven’t had to do any auto-clutch adjustments after thousands of miles on either bike, with especially brutal abuse on the Aprilia RXV. All I can say is the Rekluse folks are great to work with and these auto-clutches ROCK!!