Just another how to thread in case you have the inclination to change your clutch ramp to perhaps a Muller Power Clutch which makes clutch lever operations 40% easier....this thread also contains steps for Sportster clutch adjustment.

MULLER POWER CLUTCH




1. Place bike on a lift to set the bike upright (not on the jiffy stand) – this will prevent the oil from spilling over when you open the clutch inspection cover
2. Loosen the lock nut and lower coupling on the cable with two open end wrenches
(Magnum Stainless Steel Braided Chromite II clutch cable uses 2-7/16) to give the cable slack


3. Remove right side shifter peg mounting bolt and loosen the left side – the right side will swing down out of the way.


4. Break all clutch inspection cover screws using a star pattern to alternate screws, then remove screws using the same star pattern undoing the top screw last to help hold the cover in place until you can secure with your hand
5. Pull the outer lock nut with spring making a mental note on how the lock nut aligns to the adjustment screw.
6. Unscrew the adjusting screw by turning clockwise.
7. Turn the adjusting screw clockwise until the inner lock nut is beyond the outer ramp, then just unscrew the lock nut by turning counter-clockwise until it can be pulled out.
8. Clutch Ramp assembly – lay both inner and outer ramps inside facing you. Apply grease to the ball-bearing slots. Place together making sure the hook is on one end and the top notch is on the other end. Install retaining clip on center post groove.
9. Pull out the inner and outer clutch ramp and unhook/released from the cable.
10. Install the Muller Power Clutch by hooking the cable and inserting the inner and outer ramps
11. Screw the inner lock nut by turning clockwise as far as it can go, then turn the adjusting screw counter-clockwise until it stops, then turn back clockwise ź turn
12. Insert the outer lock nut and spring
13. Grease rubber gasket
14. Place clutch inspection cover by aligning cable slot on cover. Press cover to check for spring function. Hand screw all screws using star pattern
15. Use socket and extension to further tighten by hand using star pattern, then screw with ratchet using star pattern until it stops turning.
16. Torque each screw to 90 -120 in-lbs using star pattern
17. Install bolt in shifter peg and tighten each side to about 45-50 ft-lbs
18. Adjust clutch cable freeplay to 1/16-1/8”
19. Lower and remove lift

For clutch adjustment only, follow steps 1, 2, 4, 5, 11 just the part that says turn the adjusting screw counter-clockwise until it stops, then turn back clockwise ź turn, 12-16, and 18

Here are a couple of vids that I used as reference along with torque setting from the service manual...one vid is for clutch adjustment and the other vid is to install the Muller Power Clutch.


Job took less than an hour taking my time.

Power Clutch Assessment - not sure if it is 40% easier but it does make it easier to engage the clutch. It brings the friction point a lot closer to the grips which makes it easier on the hand i.e. less fatigue.

This thread is for reference/information only. If you are not comfortable with DIY jobs, get it done by a professional. Use your service manual and/or consult with a certified Harley mechanic. Safety first.

 

Here are pics of the outer lock nut and spring and a pic of the Muller power clutch installed.