Auto Clutch Problem

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sueyoulater

sueyoulater

Joined
Apr 29, 2005
Messages
48
Location
Eugene, Oregon
:cry: I tried to get my local mechanic to put a Rekluse auto clutch in my '03 FE400e. I find out that my late '03 has an '02 clutch and an '04 basket and the Rekluse clutch WILL NOT WORK with my bike according to the Rekluse Factory people. Apparently the shaft for this clutch has a "spline' as opposed to a "notch" and the Rekluse components would have to be custom manufactured. Also, the kick start gear has the wrong number of teeth in it. What I know about all of this makes me just a little dangerous but apparently my bike is one of about 150 that went out of the factory at the end of '03 withthis clutch combo.

My mechanic has suggested I go with a RevLoc (sp?) but I am told that I will have no clutch at all whereas with the Rekluse I still would have had a workable clutch lever to disengage the transmission.

All comments and suggestions are appreciated. :?

Syl
 
Syl,
01-03 clutches should be the same. In 04 they went to a KTM style clutch assembly which is different and is not interchangable.
Is Rekluse saying they dont offer a clutch for an 03?
Revlok makes a very good clutch (I highly recommend them). The big problem being that they are twice the price, and you must send them your clutch assembly or a good usable core. This means you are down for a week or two if you send them your clutch. Once they modify your clutch, you can not return that clutch back to it's original configuration. You would have to buy another clutch if you dont like it. You absolutely can keep you clutch on the bars as well with the Revlok and use it for a manual overide.
I am a huge fan of the autoclutch and have them in most of my bikes.
 
Sounds like a mess! don't know how to fix this problem if you decide to keep the Rekluse. Berger had one of the Revloc's in his old FC550 and liked it very much. The price on the Revloc unit is about $1000 compared to that of a $500 Rekluse though. I thought that both units were able to keep the hand clutch for use but I guess not.... Berger will most likely come along shortly to give more details or advise.

Regards,
 
What did I tell you... Berger beat me to the punch by a minute!!! :thumb:

Set this poor lad straight Berger!

Regards,
 
I can also vouch for, and highly recommend the RevLoc clutch. The current retail price is $925. I was able to get a 15% discount from the original retail price through a local bike shop. In the long run, the RevLoc is worth it.
 
well i think we as a group ough to be trying to help you get through the fog of this if you're prepared to get off yer arse and help us as well!

i need you to go into thew parts manuals and suss out exactly what you've got!

i'd have thought the outer basket was the same across but that the inner drum may have changed with the '04 model.

it is an '04 model isn't it? you haven't actually told us.

so sort out what parts are fitted from which year first.

berger has an '04 with one model fitted and i have an '02 with another so surely we can get this sorted!

regards

Taffy
 
My bike is a '03 FE 400e. If it matters, my arse is 18 pounds lighter than the last time it was of any significance to UHE gang. You all know should how sensitive I am about not having my lithe girlish figure from my youth..... :shock:

Here is what I have:

My kick start gear has 78 teeth. Not the 76 that KTM has. The clutch inner basket is an '04 KTM. The outer basket is a Husaberg '02.

According to my mechanic, he spoke repeatedly with the engineer at ReKluse and they said, and I quote, "they made these bikes for about six months at the end of the year ('03). We knew they were out there but we have never seen one. We have nothing that will make these components work together unless it is a custom build"

Question: Should I assume that RevLoc can and will do the job? Or will they run into the same problem?

Should I get a complete '04 clutch assembly, and will it work in my '03 with the 78 tooth kick start gear? Should I try to get a new "02 clutch assembly and thens end it to ReKluse/RevLoc?

My arse hurts..... :x Thanks in advance guys...

Syl
 
I would think you would be OK with the Revlok. Unother option would be to get a used assembly off ebay.
 
the outer basket is what the kickstart is meshed to so if we keep the same outer basket, you keep the same kickstart. so let's forget the outer basket and kickstart here.

you now have to worry about the inner drum, the plates and the gearbox input shaft.

i'm gonna suggest that you have a different gearbox input shaft. but we need to know. again, try and check the parts books and see which input shaft you have.

regards

Taffy
 
Not knowing **** from shinola about auto clutches.......

The Rev Loc modifies YOUR clutch, so, I wouldn't think that there would be an issue if you were to go with the Rev Loc. Seems to me there might be a reason it's more expensive......

And I DO know that many who have the Rev Loc as stated here, still have the clutch lever at the bars for an over ride if needed. Some even have added another master cylinder on the clutch side with a thumb lever so they can have their rear brake on the handle bars as well as the foot lever.

Either way, I'm sure that Taffy will help you get it sorted.
 
i borrowed berger's 550 with rekluse auto clutch on the opening day of the force ride. i never missed the lever for one second, even before i got on it i knew i'd like it and not want the lever.

i ride without it. my left bar now has a rear brake at a potal cost of £40 ($60).

you can use the rev loc but as lineweaver himself said-the simple fact is that they both do the job and the rev loc makes somebody a lot of money!

if you get it right-it'll save you some of the $500 difference tween the rev loc andd the rekluse!

i'd like to think though that people are prepared to do some of the work for themselves....

regards

Taffy
 
Taff: I appreciate all the suggestions I get. But I am not a Berg mechanic yet and this part of the machine is simply not my bailiwick.

The shaft I think you are talking about is the problem. There are apparently two options for my model year. One version had a notch on the end. The other had a splined end. Mine is the one with the spline, and that apparently is part of the problem.

Obviously, I have not taken the clutch apart myself, I am working through my mechanic and the shop manual and the exploded view on the UHE downloaded manual for 2003 Bergs.

My mechanic is Rich Wilson at KTM Country in Eugene, Oregon and he has apparently been speaking with Rick Bozarth in POrtland about this and so far it is a no go with the Rekluse. It looks like I am going to have to run with RevLoc or get another clutch that will work.

I am getting off my ass as much as I can on this. I do appreciate all the input.

Thanks again. :?

Syl
 
There isn't really such a thing as a late 03 vs an early 03. There are simply 03's. Because of the changes at Husaberg (relocating to Austria, importers etc.) the 03's were late getting to the market. Many 03's are 02 models with 03 plastic. This wasn't done by Husaberg so you can figure out from that who the culprits were.
An 03 has the Husaberg outer clutch basket, gear, and fiber plates with a KTM style input shaft, inner clutch hub, pressure plate, metal plates, and their drive pins. Seems as you will have to send in your clutch and have it modified to the Auto style. Rest easy in knowing that you have a real 03 with the updated balancer, main brgs, and rockers.
dan
 
:D Dan: and all at UHE. Thank you again for the info and support. Could I just go with a KTM outer components, then do the Rekluse or RevLoc?

I am trying to make it to Phoenix. If I do, I will bring an offering of beer....

Syl
 
Not that familair with 04, but if the intermediate kickstart gear is different, possibly the crank gear and intermediate drive gear are different as well. Something to look into before purchasing an 04 basket
dan
 
jesus dan-now go round the sheep up on your own!

:cry: :wink:

Taffy
 

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