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I was on my way on a trip up north last week when pulling off for fuel i had no down shift lingage on my 03 Road Glide. I made it back home w/ a bungee for a downshifter. anyway The cause was worn bushings in primary and stripped teeth on lever. I ordered all the new parts and JIMS tool to take out and install bushings but my problem is that Harley redesigned the shifter levers to Aluminum and uses pinch bolts & nuts to secure. My original shift levers were steel (12#) new Aluminums 4 #. Has anyone changed out levers to new lightweight aluminum? I am looking for some riders who used these new designs and there results. My original set lasted 14 yrs.
thanks
I recently had to replace mine too, as well as the shaft. It didn't occur to me that they were aluminum until I read your post, so I just grabbed a magnet, and they sure are. Ha! They work fine so far.
Just replaced my shift lever last week. around 160k miles on a 03 RKC.
While the inner primary was off the belt, clutches, swing arm isolators and chain tensioner got replaced.
Haven't had this problem but as a thought what about cutting a shallow key way in the shaft that is in the same location as the slot for the pinch bolt area. Slide in a piece of stock steel that still let's it pinch down tight. Obviously only if it's a recurring issue though.
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stripped shifter
