How was the World's First "Honda E-Clutch" Born?

In November 2023 Honda unveiled its innovative electronic clutch technology for motorcycles. Called the Honda E-Clutch, this world-first technology allows riders to start, change gear and stop without having to use a traditional hand-operated clutch lever. A bold project that was 10 years in the making, the Honda E-Clutch followed the brand’s philosophy of "Technology for people" that strives to make the joy of riding and driving available to everyone.

Despite facing a number of technical challenges and even a brief cancellation of the project, Honda’s engineers demonstrated a never-give-up attitude in their quest to perfect this pioneering technology. Here three of the key members of the team responsible for the E-Clutch reveal the behind-the-scenes story, from first idea through to production reality. Assistant Chief Engineers in Honda’s Motorcycle and Power Production Operations Vehicle Research Department, Junya Ono, Tatsuya Ryuzaki and Aska Ito, tell their stories.

What was the original idea behind the development of the Honda E-Clutch?

Ono: It's a technology designed to make riding manual transmission (MT) motorcycles even more fun. For many, the joy of riding using the throttle, brakes, clutch, and shift pedal with both hands and feet is the essence of riding. With Honda E-Clutch you can retain that joy, but without having to use a manual clutch. Whether you’re a veteran rider or a beginner, you can enjoy the same smooth getaways and seamless gear changes.

Honda was the first in the world to introduce the Dual Clutch Transmission (DCT) to motorcycles in 2010. How is "Honda E-Clutch" different from DCT?

Ito: For motorcycles equipped with DCT, there is no need for a clutch lever or shift pedal because the system takes care of these operations on behalf of the rider. On motorcycles equipped with Honda E-Clutch, riders still have to use the shift pedal to select gears and can also still use the clutch lever if they wish. Ultimately, there is no completely automatic (AT) mode, so riders need to perform the shift operations themselves, requiring the use of the left foot for the shift pedal.’

Ono: The ability to perform a manual clutch operation at any time is a significant feature of Honda E-Clutch, allowing riders to master the challenge of operating it if they wish. However, they can also choose not to use the clutch, depending on different riding scenarios, whether for comfort or a more sporty feel. As a result, many people can experience the joy of riding.

What are the benefits of the Honda E-Clutch?

Ryuzaki: ‘I believe that with the assistance in clutch operation, riding will become even more enjoyable as the E-Clutch preserves the charm of riding and controlling the bike manually. With the ease provided in cornering and other aspects, controlling the machine as intended becomes more effortless. I hope this feature attracts a lot of users.

Ono: I believe that the performance is good enough that you won't need or want to use the clutch lever under normal riding conditions. Since we kept the manual lever, even when the system is off, you can still shift. It's also possible to engage a gear while parking on a slope to prevent the vehicle from rolling down the hill, because the wheels don’t turn.’

Ito: For example, let's say you're going camping. There may be situations where the road to the campsite is unpaved and has poor footing. Thanks to the automated clutch operation, the rider can focus solely on controlling the vehicle on rough terrain without the risk of stalling. The expanded options for motorcycle touring are expected to broaden the range of activities and destinations. I hope we can expand the possibilities of new motorcycles.

There were project cancellations, the hurdle of mass production and 10 years of development. Tell us why you persisted with the development of the Honda E-Clutch.

Ono: ‘During the development of DCT we knew there was a demand for another technology, which would be simpler in design and less costly to manufacture. First, we started by leveraging the knowledge from DCT and applying that technology to develop an electronic control clutch. However, as we progressed with research and development aiming for integration into production vehicles, we faced challenges in achieving cost-effectiveness, lightweight design, and integration goals. Moreover, amidst the COVID-19 pandemic with restrictions on in-person activities, it was a very challenging project to undertake a new technology configuration in a small team and within a short period. In the continuously challenging development, there were many times when I thought, "It's impossible, we won't make it". There were many setbacks, and ultimately, the project was discontinued midway.’

Ryuzaki: At that time, however, we knew the technology was technically viable. Having had confidence that we could create something good during the development stage, it was a very frustrating experience.

Ito: ‘I joined the E-Clutch project later, having been in the mass production development group for a long time. Unlike mass production projects, a new project like the E-Clutch might not come to fruition, and so it started development without a clear future. Yet from witnessing the relentless determination of the two of them I was determined to make it a reality. Looking back now, I am grateful for the opportunity to work on projects that explore Honda's expertise and philosophy.’

Ono:? I feel that the various failures, experiences, and connections with the people involved over the past 10 years finally bore fruit as the dots were connected. I got emotional when I saw the system working smoothly during the final inspection of the assembled motorcycles at the production plant in Thailand. Despite the challenges, what we have done was not in vain.’

What challenges did you have to overcome, and how did these help you innovate?

Ono: ‘We wanted to achieve the goals of cost reduction, weight reduction, and compactness while making the E-Clutch adaptable to a wide range of models and maintaining both automatic control and manual operation when necessary. To make this happen we adopted a technology that directly controls the clutch with a motor, something that had not been tried before. However, we were able to incorporate Honda's expertise in robotics, including motor and sensor configurations and control theory for processing speed.

When considering costs, a significant decision point was determining which location would become the production base. In Honda's large motorcycle division, it is customary to produce major new technologies at domestic facilities. However, there was a keen awareness of the need to align with the internal trends for the mass production of the E-Clutch. Therefore, we proceeded with considerations for applying it to models produced in Thailand, which would be advantageous in terms of cost. To succeed in this challenge, we overcame language barriers, engaged in numerous discussions, and matured the specifications.

To speed-up the development, we introduced Model-Based Development (computer modelling) - a technique commonly used in the development of automobiles - for the first time in Honda's mass-produced motorcycles. Furthermore, we conducted numerous test rides, taking the prototype to Europe for trials, allowing participants to experience the allure of the system.

Honda has the slogans “The Power of Dreams” and “How we move you.” What dreams do you have for the future?

Ito: ‘I wanted to work in technical development when I was looking for a job. I considered various fields for development, including home appliances, but what intrigued me about emotionally driven mobility, such as motorcycles used as a hobby, is that it can show various facets depending on the customer and the usage scenario. That's why I joined Honda. I want to continue advancing motorcycle technology as products that stimulate human senses, offering pure enjoyment.

Ryuzaki: ‘This development experience has elevated our technical expertise and contributed to our personal growth. While we are grateful to the company that gave us a chance despite being initially discontinued, we hope to repay that gratitude by bringing smiles to people worldwide through Honda-style products and services.’

Ono: ‘I have always wanted to develop technology that can change the world. If we are going to do something, I have always believed that we should not just follow the path that our predecessors have paved, but rather, we should do something that only we can do. I want to make customers happy with that technology, create something even more enjoyable. With that determination, I joined Honda, so perhaps the slogan "The Power of Dreams" naturally resonated within me. I want to continue creating technologies, products, and services that can change the world in the future.’