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.

 

you can drive those bushing out with a socket a 11/16 craftsman's fits mine

 

Not that it helps your cause. The shifters on my 2007 Ultra are steel. Almost one year and 8,000 miles later. Still good.
https://www.hdforums.com/forum/touri...ter-lever.html

 

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.