Light Clutch Parts & Service

Installing Harley�s new clutch release

For 2006, Harley-Davidson introduced its new �reduced effort� motorcycle-clutch system on all models. The factory claims that it takes 45 percent less effort to yardin the Clutch lever on its 2006 Twin Cam models. Engineers accomplished this by changing three areas of the Clutch system: the Clutch spring, Clutch release inner and outer ramps, and the Clutch cable. The
new spring has been changed so that it requires less travel to release; the inner and outer ramps have a reduced angle on their ball ramps; and the Clutch cable is now Teflon lined to cut down on friction.

After riding the 2006 models I can honestly say it works. All of the bikes feel as if their Clutch lever effort has been halved, and the Clutches all engage very crisply. You no longer need to be a body builder to be able to comfortably squeeze the Clutch lever. Harley-Davidson now offers a reduced effort Clutch kit, part No. 36808-05; it fits all 1999 through 2005 TC88 models.

The kit includes two of the three parts used in the 2006 models: the Clutch spring and the Clutch inner and outer ramps. If you want to go for the whole package, you can order one of the new cables for your model bike. Installing the reduced effort kit requires that the Clutch release cover be removed from the right side of the transmission, and removing the outer primary cover to gain access to the Clutch assembly. Since the primary cover must be removed,
this is a good time to consider installing the new automatic primary chain tensioner. For
more information see your dealer.




LIGHT CLUTCH

The new Harley-Davidson Reduced Effort Clutch Kit has three components:
the Clutch spring and inner and outer release ramps. The spring fits on the end of the Clutch itself inside the primary cover, and the ramps go inside the Clutch release cover. The release ramps work with three steel balls to convert the rotary motion of pulling the Clutch cable into a pushing force on the end of the Clutch pushrod.

A rather large internal snap-ring holds the ramps inside the Clutch release cover. The inner ramp is locked in a stationary position by a tab on its outer surface that fits into a notch in the Clutch release cover. The three balls are seated in tapered grooves in the inner ramp. The outer ramp fits over the balls and rotates around a central pivot. As the Clutch cable pulls the outer ramp, the balls move in each tapered groove. This movement of the balls in the grooves causes the balls� position to go to the shallow section of each groove, forcing the outer ramp outward against the Clutch release rod. The new reduced effort inner ramp has longer tapered grooves than the 1999 to 2005 inner ramp.

The longer grooves have a gentler angle than the old part; this requires less force to move the balls up the ramps. The new Clutch spring mounts over the end of the pressure plate. The Clutch spring is sandwiched between the pressure plate and the spring retainer; it is secured with six metric bolts.

This article reprinted with permission from American Rider Magazine. Go to www.americanrider.com for more information on your two-wheel lifestyle.