Shift lever replacement

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Aug 30, 2022 | 09:22 AM

#11

Max Headflow

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Joined: Dec 2005

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From: poway

Quote:

Originally Posted by glasspilot

I think HD made the original lever TOO BEEFY. In other words it takes a lot of torque to close that little gap to tighten on the shift shaft. If Harley removed some material around the area it would be more flexible and require less bolt torque to securely tighten around the shift shaft. What's amazing to me is that this has been a problem for years and HD hasn't really addressed the issue. It takes the aftermarket (Baker and Better Lever) to come up with a solution.

I think they finally figured it out late 2010s. It took them a while.. It's when the M8s came out..

Last edited by Max Headflow; Aug 30, 2022 at 09:41 AM.

Aug 30, 2022 | 12:02 PM

#12

foxtrapper

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Joined: Nov 2012

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From: USA

FWIW, my 04 had a loose lever. As I had a seeping seal and a few other things to do, I went ahead and pulled the primary.

Anyhow, since the shaft and lever were fine, I experimented a little.

I could not create enough torque with the Allen screw to pull the lever tight on the shaft. Switching to a hex bolt, it was no problem to pull the lever tight on the shaft.

Aug 30, 2022 | 02:47 PM

#13

hattitude

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Joined: Sep 2008

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From: San Diego, CA

Quote:

Originally Posted by foxtrapper

FWIW, my 04 had a loose lever. As I had a seeping seal and a few other things to do, I went ahead and pulled the primary.

Anyhow, since the shaft and lever were fine, I experimented a little.

I could not create enough torque with the Allen screw to pull the lever tight on the shaft. Switching to a hex bolt, it was no problem to pull the lever tight on the shaft.

When I first read about this issue many years ago, I believe on this forum, that was the recommendation made by many....

To swap out the allen head for a Hex head and really torque it down....

Aug 30, 2022 | 03:20 PM

#14

Max Headflow

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From: poway

Another simple thing to do is simply slip an AN style washer under the socket head cap screw with a little grease or antisleeze.

Aug 30, 2022 | 03:24 PM

#15

Uncle Larry

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From: Michigan 15 Minutes East Of Hell

"AN style washer" ... I can see some Googling this and coming up with a Maytag :>)

Aug 31, 2022 | 03:02 PM

#16

caulk04

Thread Starter

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Joined: Jul 2016

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From: Transfer, PA

Quote:

Originally Posted by foxtrapper

I could not create enough torque with the Allen screw to pull the lever tight on the shaft. Switching to a hex bolt, it was no problem to pull the lever tight on the shaft.

I'd say you can get plenty of torque through the allen bolt, but not once it's lived in there for who-knows how long and has a little corrosion in the threads. The only bolt I was able to grab on short notice was, coincidentally, a normal hex head but it required FAR less force to finish the job than I had initially tried applying to the original bolt. In fact I just about trashed it trying to get it out. The slippery loctite helped, no doubt.

Aug 31, 2022 | 08:00 PM

#17

foxtrapper

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Joined: Nov 2012

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From: USA

Clean threads, good Allen screw. Before it started pulling the split lever tight around the shaft the screw head started yielding at the Allen wrench contact points.

The conventional bolt suffered no such damage and pulled the lever tight onto the shaft.

Not surprising, since the diameter of a standard bolt head is much larger than an Allen head.