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[HOGMIKE]

Forgot one

[Eqcons]

I used my stock master cylinder. The muller cost me a little more, coming from Germany!
Here are some photos of my stock slave cylinder after I robbed the spring and rubber gasket.

AIM insist that with theirs, you need to change to the '16-up master cylinder, but they only make the one slave cylinder.  Mueller don't need the master cylinder change, but they do make two slave cylinders, of course.

[grc]

IMHO most of the problems with engagement point and friction zone began when Harley switched to their lame "Assist & Slip" clutch.  Recently people have found a new seat for the damper spring from the 2019's that can be installed to move the engagement point closer to the bar instead of out at the end of lever travel, and that alone can help with modulation of the clutch engagement.  It's a cheap fix if it works for you.  The friction zone can also be affected by the primary lubricant you use and the amount of said lubricant.

https://www.cvoharley.com/smf/index.php?topic=117734

Jerry

[Eqcons]

Thanks Jerry,  yes, I'd seen that, but it seems to mainly deal with moving the engagement point closer to the bars (a good thing), but it's the lack of friction zone that's the killer for me.

Bike came with Syn3, of course, and since then I've run Redline V-Twin primary, and the newer Formula+, as well as having changed the clutch out itself for a Rekluse automatic clutch. Nothing makes any difference to the friction zone, it really hardly exists.

[grc]

You may find that the engagement control mproves once the engagement point is fixed, others have made that comment.  With engagement occurring all the way out at the end of lever travel, you can experience a more abrupt light switch type engagement due to how your hand works.  If you're like most people with normal sized hands, your hand control of the lever is more precise in the mid range of travel, not with your fingers almost fully extended.  It might be worth a try, just thought I'd throw it out there.

Jerry

[HOGMIKE]

You may find that the engagement control mproves once the engagement point is fixed, others have made that comment.  With engagement occurring all the way out at the end of lever travel, you can experience a more abrupt light switch type engagement due to how your hand works.  If you're like most people with normal sized hands, your hand control of the lever is more precise in the mid range of travel, not with your fingers almost fully extended.  It might be worth a try, just thought I'd throw it out there.

Jerry

You have a point there as the clutch parts have changed over the past few years.
My experience started with clutch packs from 2009, 2010, 2014, 2016, 2017, 2019
These have all been the same model and I never noticed any issues until I got the 2017.
You mentioned “light switch”. I think that describes how mine was working. I prefer a longer lever travel before fully engaged, more controllable for me. Easier to “slip” the clutch.
JMHO of course!
 

[Eqcons]

I've had CVO Hydraulic clutch models from 2005, 2007. 2009 and they were fine. The 2014 is when it all went horribly wrong for me.   I may try the damper spring method though.

[Eqcons]

IMHO most of the problems with engagement point and friction zone began when Harley switched to their lame "Assist & Slip" clutch.  Recently people have found a new seat for the damper spring from the 2019's that can be installed to move the engagement point closer to the bar instead of out at the end of lever travel, and that alone can help with modulation of the clutch engagement.  It's a cheap fix if it works for you.  The friction zone can also be affected by the primary lubricant you use and the amount of said lubricant.

https://www.cvoharley.com/smf/index.php?topic=117734

Jerry

OK, I've replaced the damper spring seat with the new part #, and I can say right away that the difference in engagement point is miraculous.  Now much, much closer to the bars.  I'd recommend this from that aspect alone.  I've only ridden 30 miles since I did the job a couple of weeks back, so not enough miles yet to say what the friction zone feels like, but it's a HUGE improvement in the clutch even if the friction zone turns out not to feel any different.  The clutch does feel like there's less pull effort in the lever, but I must be imagining that. Hard to believe that just a few thou of metal thickness can make such a big difference.

As people have been complaining about this since 2014, just like the cruise control and PTT switches being on the wrong side, and the self destructing water pump design, I suppose we should be surprised that it's taken so long to remedy these things, with the clutch taking longest, but then you think "nah, it's HD after all, with the old "Problem? What Problem" attitude." 

The downside, for me, is that I had to go back to the standard clutch pack, losing my Rekluse auto clutch, as it doesn't use the judder spring or seat.