happened to me first ride after i extended my forwards and put a longer linkage on..this was when i first bought the bike and didnt carry tools yet, luckly a guy a on dyna was wiser and had a good set on his bike...got it back in and since then i have carried tools

 

Same experience here, although I was fortunate enough to never have it fall off. Mine was loose on the end of the pinion from the day I bought it ('09 FXD). I would always notice how the linkage would shake with the bike's idle but would check it and it was secure enough not to slide off the end of the pinion.

It went through 1k and 5k service in that condition until one day I got to really looking around down there. Found that the lever had been secured too far toward the outside--the set screw was not in the groove in the middle portion of the pinion. I spent a good amount of time and foul language getting the set screw out using a standard allen key with vise grips clamped on the shorter end of the "L" for leverage (the length of the longer end was needed to reach down in between the trans and primary to the set screw). When i finally got the screw out I checked to make sure the pinion teeth weren't shot, and then slid the lever far enough on the pinion so the set screw went into the groove. Secured it with loctite and it's stayed tight for the last ~10k miles but I still occasionally check if there's play in the linkage or glance down at it to see if it's shaking/loose again.

 

bungking.com sells a mid ctrl adjustable shifter linkage. i installed one a couple weeks ago and really like it.

 

I'm not sure, but if you're talking about the part I circled below, I did have this problem a couple of times. It never actually fell off, but it definitely got close to that. I took it to the dealer several times before they got it right. They had to tap the hole deeper than it was from the factory, because it couldn't tighten enough to put enough pressure on it to keep it in place. It's been fine since then.

 

I'm going to replace the current joints with the heim joints. The little ball joints have a habit of breaking at bad times. You can get the heim jonts at Mcmaster Carr for $5.47 I think and get the other hardware at home depot or somewhere. Here is a link about them from the touring section https://www.hdforums.com/forum/touri...rod-lever.html