200 xc-w Rekluse Z-Start Pro Installation

The information provided is not intended to "replace" the Rekluse Manual but rather to supplement it with additional pictures and information specific to the 200 xc-w. When in doubt refer to your Rekluse Manual or contact Rekluse directly.

First lay the bike on it's side. You must do this for two reasons: it prevents oil from spilling and it makes assembly of bearing balls onto pressure plate possible.

The brake pedal should be moved out of the way. You can do this by removing the swivel head bolt and removing the swivel head/push rod assembly.

Remove swivel head/push rod assembly.

Unclip the spring from the brake pedal.

The brake pedal out of way. Clutch cover ready to be removed.

Clutch cover removed.

Remove the clutch springs and bolts and remove the OEM pressure plate.

OEM pressure plate removed. Pointer showing the throw-out.

Removing the throw-out and rod.

Remove the clutch pack. (friction disks and drive plates)

Separate friction disks from drive plates. You will re-use the friction disks.

Un-bend the tabs away from the center clutch nut.

Another tab that is in the way of removing the nut.

You can remove the center clutch nut using an impact wrench; you can also use a clutch holding tool; another method is to have someone apply pressure to the rear brake while the bike is in 5th or 6th gear. I tried the latter with my wife but she didn't have enough strenght in her leg to keep the wheel from turning, so I resorted to jamming the wheel as pictured above. You must be EXTREMELY CAREFUL not to bend the spokes or damage anything ie. the rotor.

Breaking loose the 27mm center nut with a breaker bar. The nut has regular right hand threads.

Set the 27mm nut aside. It will be re-used.

Remove the tab lock washer. It will NOT be re-used.

The OEM center clutch hub is removed. Be extra careful not to lose the thrust washer as it may be stuck behind the OEM center clutch hub and it could fall into the transmission. Put it back on the shaft. It's needed for correct clearance.

installing the Rekluse center clutch hub.

Rekluse center clutch hub in place.

Rekluse tab lock washer. Pointer showing the center tab. You will bend the center tab down over the flat side of the Rekluse center clutch hub. See picture below.

The flat side of the Rekluse center clutch hub. Here you bend the center tab of the Rekluse lock washer.

Bending down the center tab. The 27mm nut is loosely intalled to keep the lock washer in place. It made bending the tab easier.

Torquing down the 27mm center nut to 130Nm (~95 Ftlbs)

Bend up the remaining two tabs on the lock washer after torqing the nut with a torque wrench.

Prepare Rekluse steel drive plates.

Place 1 Rekluse steel drive plate in the center clutch, per Rekluse instructions. (Although, I have to admit I'm not sure why they want you to do it that way)

Prepare the remaining drive plates and OEM friction disks to be installed with each steel plate to be followed by an OEM friction disk. Basically, you start with a Rekluse steel plate and end up with an OEM friction disc on top of your stack.

last OEM friction disk being installed.

Now that all the drive plates and fricion disks are installed you are ready for the next step. Prepare the remaining Rekluse components for installation starting by removing the 2 torx head screws.

Rekluse components ready for installation.

Start with Rekluse lower assembly. Note that there are 4 cut-outs. 2 out of the 4 cut-outs will mate (index) with 2 tabs in the center clutch.

Tab in the center clutch. This is where the cut-out from the lower assembely will go.

Another tab. The 2 tabs are 180 degrees from each other.

Properly seated lower assembly. Both tabs and cut-outs should look like this.

Installing the retaining ring. Note the scalloped (skinny/sharp) end. It must be installed clockwise as pictured.

2 different ends of the retaining ring. The scalloped end goes on clockwise.

The retaining ring in the groove. "Use a screwdriver to ensure the ring is seated by sliding along the ring's inner diameter". This is EXTREMELY IMPORTANT.

Re-stalling the clutch push-rod.

Re-installing the throw-out.

Installing the Rekluse throw-out spacer.

Rekluse throw-out spacer in place.

Install the Rekluse C200 spring of your choice. (see Rekluse manual for spring configuration) Pictured is the C200-L3.

Now you're ready to install the steel balls onto the Rekluse pressure plate. Put a little bit of motor oil in the grooves to help with the break-in process. It also helps to keep the balls in place.

Away from the bike install the balls in the pressure plate. See Rekluse manual for your choice of ball configuration.

VERY CAREFULLY install the pressure plate with balls making sure the holes line up with the posts and the outer tabs of the Rekluse pressure plate line up with the basket slots. You will feel the resistance of the C200 spring

Make sure the outer tabs of the pressure plate line up with the basket slots.

Install lightly 2 torx head screws while pushing down on the top plate and pressure plate working against the resistance of the C200 spring and the hydraulic clutch.

Attempt to slide the short ends of the NO-GO wire gauges between the Rekluse pressure plate and the top OEM friction disk 180 degrees from each other. (red arrow pointing to location 180 degrees from NO-GO wire gauge) Make sure to stick them in deep enough so that you are on the friction material of the OEM friction disk and not just on the outer edge or you will get a false reading. If you are UNABLE to slide both wire gauges easily THAT IS A GOOD SIGN.

If the wire gauges slide in smoothly that means that the clutch pack needs adjustment. You will need to install the thicker steel plate provided in your kit. Simply swap that thicker steel plate for the top steel drive plate and re-check clearances using the wire gauges.

Use the short end of the NO-GO wire gauge to check for proper clearance.

Install the rest of the torx head screws using the Loctite 243 provided in your kit. Torque to 14 in-lbs. Dont forget the 2 screws originally installed without Loctite. Unscrew them, apply Loctite and torque them down.


If you are re-using the stock clutch cover you will need to install both gaskets provided in your kit in order to have the correct clearance. If you are using the Rekluse cover you can re-use (if in good condition) or get a new OEM clutch cover gasket. Make sure to follow break-in procedure outlined in your Rekluse manual.

Happy Trails!

UPDATE: I changed the C200 spring from C200-L3 to L2. Clutch engages alot sooner, but there is also significantly more "drag" at idle. Overall I prefer the L2 spring.