my 2011 flhtc had the same problem, i pulled it of and took a dremmel tool and took some metal out of the slot so the pincher would pinch more..

 

Does anyone know what year this recess started?

 

+1 on better lever....... I had a bobber with an ultima tranny..... Stripped the shift shaft...... That better lever TOTALLY solved the problem. I was gonna replace the whole shaft, but cut the old one out wih a dremel and installed that thing.

 

I have used a hack saw blade to widen the slot. Works just as well as a dremel.

 

The Better Lever is an option, however I have "repaired" several of these by simply removing the pinch bolt, cleaning the threads, applying a bit of Loc-Tite to the threads and re-torquing the bolt. I've seen many try to just re-tighten the bolt with little success, but the process I listed above really does work. You've got nothing to loose. Give it a try.

 

Larry advice is spot on have repaired levers using his technique!

 

I replaced mine with the Better Lever in 2010 after coming back from Sturgis. I rode the last 300 miles stuck in 5th gear. Although the Better Lever is expensive it's cheaper than a HD replacement. It took around 30 minutes to replace including cutting off the old lever with a dremel.

 

Thanks again guys, all this is advice I needed!
Roy

 

My owners manual says over and over again that excessive force of the shifter will cause damage. I have no idea if this is what they are talking about or not, but every new machine I have seen needed the arm tightened within the first 5000 miles. Just seems to be the way the factory does things. Once done it seems to last for ever, or at least through the 60,000+ I have on mine now, still tight.

 

Just completed the lever replacement on my 2012 FLHR, dealer insists the inner primary has to be pulled, bunch of BS. Used a new Allen with a short extension as my pinch bolt was frozen and twisting, loosened and tightened till I got it to turn, got behind the lever with a screwdriver and popped off lever, fell on the floor. I used a replacement lever but didn't need to old lever was fine, pinch bolt stripped from manufacturer. Lube shaft,slip on lever and tighten till you turn blue. 15 minutes total. 9000 miles on bike. No better lever needed. To expensive. $225 I don't think so . If you want a better lever get a Baker lever. About $65