I have an 07 ultra classic. My forward shift lever keeps coming loose on the shaft it tightens to. The shaft itself has a little play side to side but I can put the lever back on and it doesnt take long for it to fall off the spline and drop down beside th floorboard. Is there an easy fix or will I have to replace the shaft and if so how much trouble is that. Thanks for any help.

 

It's the softer metal in the lever that makes it loosen up. I think they do that to keep the shaft from wearing, ( Easier to replace the lever.)

I'm on my second lever. First one lasted 11 yeras and 100,000 miles.

I keep it tight with a grade 8 bolt with blue Loctite and CHECK IT every time I clean the bike. For me that's once a week or so.

I also carry a tool kit that includes that particular hex allen because twice before my rigid inspections, that lever came off in less than ideal circumstances.

Bottom line, check it regularly. There can be no wiggle or you're about to lose it.

 

Remove levers completely. Place a rubber type spacer between the front lever & primary. Then install with locktite.

 

Sounds like the splines on the shaft or lever could be worn if the bolt is tight.

It's easy to remove/replace the shaft by removing the lower bolt on the front shift arm.Good idea to do this once in a while to lube the shaft that goes thru the case.

 

I'd replace the shaft and get things tightened up. It will eventually lead to the rear loosening and then the wobbly effect will lead to a shifter shaft seal leak and so on. Preventative maintenance.

 

It's not major surgery to replace the front shifter shaft and ( if the shaft is loose in the housing, the bushings ) the shift lever. On my 92 FLHTCU I encountered this problem and after replacing the first assy ( at about 25,000 miles ) it happened again ... The next shaft and shifter that I purchased had a heavier boss area on the shifter and a larger bolt that tightened the shifter to the shaft ... a little bit of Loc-Tite helps also.

http://partsfinder.onlinemicrofiche....IFTER-ASSEMBLY

 

Your shift lever shaft should be fine, you should replace the arm... http://www.ebay.com/itm/Heavy-Duty-I...4602%26ps%3D54
Odds are the arm teeth are worn.

 

Spray the shaft spline and the lever with brake cleaner. If there's any oil on either it won't stay tight.

 

Take the HD allen screw out and replace with a Grade 8 5/16-24 x 1" UNC Hex .... a much improvement head for tightening than the H-D Allen head., H-D part# is

....for the gear shifter rod gearbox end # 3 on the diagram?

also this is better than standard soft metal HD lever. http://www.ebay.com/itm/Heavy-Duty-I...4602%26ps%3D54

 

Here are the threads I have on the subject from my archives:

https://www.hdforums.com/forum/touri...he-tranny.html
https://www.hdforums.com/forum/touri...ift-shaft.html
https://www.hdforums.com/forum/touri...ift-lever.html