2009 Buell 1125CR

ODI opened this investigation based on 25 allegations of subject motorcycle stalling, without warning, due to charging system failure (typically involving the stator).As part of this investigation, testing was conducted to assess whether there would be areasonable warning prior to stator-related engine shut-down while underway.A memo describing this testing may be found in the public file for this investigation.Given the relative frequency of alleged stator failures involving Buell 1125's, it is apparent that customers may not be satisfied with their motorcycle.An example of a manufacturer responding to this type of dissatisfaction is found in the Harley Davidson December 7, 2009product improvement campaign to address the stalling issue.However, current test data does not establish that this customer satisfaction issue is also a safety defect that results in an unreasonable risk to motor vehicle safety.In the absence of a safety defect trend related to Buell 1125 charging system failures, this investigation is closed. The 62 ODI complaints we cite may be found by entering the following ODI investigation numbersat www-odi.nhtsa.dot.gov/owners/SearchNHTSAID:10373814,10386008,10397985,10406939,10406967,10406969,10407046, 10407318,10407511,10407672,10410524,10411954,10429450,10429467, 10429481,10429488,10429530,10429531,10429964,10429970,10429985, 10429987,10430176,10430736,10432169,10432891,10445118,10452480, 10457062,10457815,10457829,10462420,10462439,10462834,10463008, 10463483,10463664,10465165,10465225,10465226,10466505,10470386, 10470415,10470428,10473664,10474136,10474363,10479428,10484793, 10494949,10495197,10496446,10496804,10497643,10496127,10496088, 10496048,10496022,10496018,10495355,10495331,10495307

We opened this PE based on a single complaint of rapid fuel expulsion while re-fueling from the owner of a Buell 1125CR.After opening this PE, we contacted other owners, Buell dealer service departments and monitored activity of various Buell-related web forums.While Harley Davidson (Buell was a subsidiary) has no owner complaints, it did receive four warranty claims related to this issue.Two involve the fuel line check valve, one a pinched fuel vent hose, and one saturated charcoal cannister due to over-fill.Currently, the data does not indicate a trending safety defect exists.We will continue to monitor this issue and take action as appropriate.

AS I WAS RIDING AT 40-45 MPH I NOTICED A BATTERY LIGHT COME ON. SHORT TIME LATER MY DISPLAY READ (SYSTEM VOLTAGE) WITHIN MINUTES EVERYTHING ON MY BIKE SHUT OFF INCLUDING ENGINE ABRUPTLY NEATLY TOSSING ME OFF THE BIKE. THANKFULLY, I MANAGED TO STAY ON AND SAFELY (ONLY BECAUSE DRIVERS WERE PAYING ATTENTION) WAS ABLE TO GAIN CONTROL AND STOP. MY BIKE AT THIS TIME HAD 3800 MILES. HARLEY REPAIRED THE ISSUE THAT THEY SAID WAS A BURNT STATOR THUS DEPLETING MY BATTERY OF ANY POWER. I'M GREAT FULL I WASN'T ON THE FREEWAY! AFTER SOME RESEARCH THIS HAS HAPPENED TO 100% OF THE 2009 1125CR'S AND R'S. THIS IS A DANGEROUS ISSUE AND SHAME ON HARLEY DAVIDSON FOR NOT CARING AND DOING THE RIGHT THING! ALSO SHAME ON NHTSA FOR NOT PROTECTING THE CONSUMER!!! WHAT MORE IS NEEDED??? 100% OF THESE STOCK BIKES HAVE THIS ISSUE!!! WWHY IS THIS NOT RECALLED??? IS IT CAUSE HARLEY IS A MULTI-MILLION DOLLAR BRAND??? PROTECT THE CONSUMER, DO YOUR JOB!!!!!!!!

NHTSA ID

11091489

Incident

Dec 1, 2017

Mileage

3,800 mi

ELECTRICAL SYSTEM OVERHEAT SITUATION, BURNT STATOR DUE TO OVER HEATING ON A POORLY DESIGNED CHARGING SYSTEM. I'M NOT THE FIRST AND DEFINITELY NOT THE LAST WITH THIS ISSUE THAT HARLEY DAVIDSON CHOOSES TO OVERLOOK INSTEAD OF FIXING THE PROBLEM. FOR THE FEW OWNERS THAT HAD THIS REPAIRED UNDER WARRANTY, HD ONLY CHANGED THE BURNT PARTS WITH THE IDENTICAL REPLACEMENT WHICH FAILS AGAIN ON NEARLY ALL REPAIRED BIKES. ERIK BUELL RACING HAS COME UP WITH A PARTIAL FIX BUT, THAT COST ($455) COMES OUT THE OWNERS POCKET, NOT THE MANUFACTURER. PLUS THE COST OF OTHER PARTS, STATOR REBUILD, GASKETS, SPECIFIC TOOLS NEEDED TO COMPLETE THE REPAIR PROPERLY. *TR

NHTSA ID

10505412

Incident

Jun 6, 2012

Mileage

1,700 mi

MOTORCYCLE LOST POWER AND STALLED AT INTERSECTION UPON ACCELERATION. *TR

NHTSA ID

10504118

Incident

Apr 11, 2010

Mileage

1,000 mi

PRIOR TO THE FIRST INCIDENT THE MOTORCYCLE HAD BEEN RUNNING FOR ABOUT AN HOUR TRAVELING AT A CONSERVATIVE SPEED BEHIND A LEADER OF A PACK OF RIDERS. THE VEHICLE WAS PARKED AT A LOCATION WHERE THE AIR TEMPERATURE WAS ROUGHLY 45 DEGREES F FOR ABOUT 30-45 MINUTES. UPON ATTEMPTING TO START THE MOTORCYCLE, POWER WOULD SUCCESSFULLY CYCLE AND THE ELECTRIC STARTER SWITCH WOULD PRODUCE CRANKING WITH THE OPERATING SWITCH ENGAGED AND KEY TURNED TO ON, BUT THE VEHICLE HAD A CONSIDERABLE AMOUNT OF TROUBLE GETTING TO AN OPERATIONAL IDLE STATE. THE ELECTRICAL SYSTEM'S ABILITY CONTINUED TO DETERIORATE, RESULTING IN MORE DELAYED STARTS AND SEVERELY IMPACTED OPERATING INTEGRITY. DURING MOVING OPERATION, THE MOTORCYCLE'S LCD DISPLAY BACKLIGHT WOULD EXTINGUISH ALONG WITH THE HEADLIGHTS. THE RPM NEEDLE WOULD REGULARLY DROP TO 0 AND STAY THERE, MAKING IT DIFFICULT FOR ME TO KEEP THE MOTORCYCLE AROUND 5000 RPMS (RECOMMENDED OPERATING RPM TO PRESERVE LIFE OF NOTORIOUSLY DEFECTIVE STATOR). THE VEHICLE PRESENTS A BUCKING AND JERKING MOTION WHILE OPERATING AT CONSERVATIVE SPEEDS (UNDER 6000 RPMS ACCELERATING VERY GRADUALLY), RESULTING IN SPORADIC ACCELERATIONS/DECELERATIONS AND REDUCTION OF OPERATOR CONTROL. THE MOTORCYCLE HAS COMPLETELY LOST POWER ON 4 SEPARATE OCCASIONS IN DANGEROUS ENVIRONMENTS, AND 7 TIMES WITH RELATIVELY SAFE SURROUNDINGS. THE MOTORCYCLE IS CURRENTLY IN A STATE OF SOLITARY NON-OPERATION (NEEDS EXTERNAL POWER SOURCE TO START) AND I DO NOT FEEL RESPONSIBLE RIDING IT. THIS IS A WIDESPREAD ISSUE AND SOMETHING NEEDS TO BE DONE ON THE MANUFACTURER'S BEHALF IN TERMS OF RECALLING THE STATOR ASSEMBLY AND OTHER ELECTRICAL COMPONENTS THAT ARE WELL-KNOWN FOR THEIR FAILURE. BUELL FORUMS ONLINE CLEARLY REFLECT THIS, THEY CAN BE CITED UPON REQUEST. *TR

NHTSA ID

10501326

Incident

Jan 16, 2013

Mileage

9,800 mi

AT AROUND JULY 24TH, 2011 I WAS RIDING MY 2009 BUELL 1125CR HOME AT ABOUT 1AM FROM EASTON, PA. AS I CROSSED INTO NJ MY BATTERY LIGHT CAME ON SO I PROCEEDED TO HEAD HOME WITH ABOUT 20 MILES TO GO. AS I GOT TO MY EXIT OFF THE HIGHWAY (1.5 MILES FROM HOME) THE BIKE SHUT OFF AND SYSTEM VOLTAGE APPEARED SHORTLY BEFORE. I MANAGED TO GET OFF THE HIGHWAY AFTER THE REAR TIRE LOCKED UP CAUSING A SUDDEN SKID OF THE REAR TIRE. I FOUND THAT THE BIKE HAD NOT BEEN CHARGING DUE TO A BURNT OUT STATOR AND FAILED CHARGING SYSTEM. 8 MONTHS LATER AROUND THE MIDDLE OF MAY, 2012 I HAD TAKEN A TRIP DOWN TO FLORIDA AND AFTER 2,000 MILES THE CHARGING SYSTEM FAILED AGAIN AS I WAS STRANDED IN DAYTONA. I MANAGED TO GET MY BIKE JUMP STARTED AND RIDE TO THE NEAREST HARLEY DAVIDSON/BUELL DEALER WHERE I HAD TO SPEND $300 ON A NEW BATTERY AND CHARGING RELAY. THIS WAS AT ABOUT 14,000 MILES ON THE ODO. SINCE THEN I HAVE BEEN HAVING CONTINUOUS ISSUES WITH THE CHARGING SYSTEM AND REMOVED THE RECALLED CHARGING HARNESS WHICH SEEMS TO HAVE FIXED THE ISSUE FOR NOW. BUT I AM STILL WORRIED IT WILL HAPPEN AGAIN IN THE FUTURE. *TR

NHTSA ID

10500664

Incident

Jul 24, 2011

Mileage

5,400 mi

JUST BEFORE TURNING SOUTHBOUND ON H 75 IN DEWEY OKLAHOMA, MY MOTORCYCLE DIED COMPLETELY. HAD I COMMITTED TO THE TURN AND ENTERED THE HIGHWAY, I WOULD HAVE BEEN LEFT WITHOUT POWER WITH ONCOMING HIGH SPEED TRAFFIC. THE PROBLEM TURNED OUT TO BE A FAILED STATOR IN THE ELECTRICAL SYSTEM. MY MOTORCYCLE HAD PREVIOUSLY BEEN SERVICED BY ROUTE66 HARLEY DAVIDSON IN TULSA TO INSTALL A CORRECTIVE WIRING HARNESS TO FIX THIS KNOWN PROBLEM, BUT APPARENTLY THE CORRECTIVE ACTION WAS INEFFECTIVE. *TR

NHTSA ID

10500131

Incident

May 15, 2012

Mileage

6,000 mi

THE STATOR AND ELECTRICAL SYSTEM STARTED GIVING ME ISSUES SINCE I HAVE OWNED THE BIKE. I FIRST HAD MY VOLTAGE REGULATOR GO OUT ON ME. I THEN HAD THE WARRANTY HARNESS UPGRADE WHICH WAS SUPPOSED FIX THE ELECTRICAL PROBLEMS, BUT IT DIDN'T. PRIOR TO MY STATOR FAILING, THE VOLTAGE WOULD NOT GO ABOVE 11.9 WHICH IS TOO LOW. THE STATOR EVENTUALLY OVER WORKED ITSELF AND MELTED INTERNALLY. THE BIKE STARTED BACKFIRING LOUDLY, LIGHTS AND ELECTRICAL SYSTEMS GOT VERY DIM AND THE BIKE WAS EXTREMELY HOT AS IT WAS NOT RUNNING PROPERLY. I STOPPED THE BIKE FOR A MINUTE FOR IT TO COOL DOWN. AFTER I DID THAT THE BIKE WOULD NOT START AND STRANDED ME ON THE ROAD 20 MILES FROM HOME. THIS IS A KNOWN ELECTRICAL ISSUE FOR 2009 1125CR MOTORCYCLES. THE FIX AND LABOR COST FOR THIS WAS WELL OVER $1500 AND QUITE THE PAIN AND HASSLE. *TR

NHTSA ID

10499715

Incident

Jul 31, 2012

Mileage

10,060 mi

ON FEBRUARY 21, 2013 AT 10:40PM, I WAS TRAVELLING NORTH ON INTERSTATE HIGHWAY TO WORK WHEN MY INSTRUMENT CLUSTER WHICH READS MY SPEED AND VEHICLE GAUGES TURNED OFF AND MY LOW-BEAM HEADLIGHT BULB FLASHED AND BURNED OUT, CAUSING ME TO LOSE SIGHT OF THE ROADWAY TEMPORARILY. I SWITCHED MY HIGH-BEAM HEADLIGHT SWITCH TO HAVE LIGHT TO SEE THE ROADWAY AND A SECOND LATER, IT ALSO FLASHED AND BURNED OUT, AS IF MY ELECTRICAL SYSTEM WAS FAULTY, AGAIN. THIS HAPPENED AT MILEAGE 4551. I JUST RECENTLY HAD THIS SYSTEM SERVICED WITH ANOTHER VOLTAGE REGULATOR AT MILEAGE 4488, WHICH MEANS I ONLY TRAVELLED 63 MILES ON THE NEW VOLTAGE REGULATOR. I WAS ALMOST INVOLVED IN AN ACCIDENT AT MILEAGE 4480 WHEN MY ELECTRICAL SYSTEM TURNED OFF DURING OPERATION AND NEARLY HAD ANOTHER VEHICLE STRIKE ME FROM BEHIND WHEN VEHICLE ELECTRICAL SYSTEM TURNED OFF AND STALLED VEHICLE IN TRAFFIC. THIS IS A SAFETY HAZARD AND NEEDS TO BE REPAIRED BY MANUFACTURER. THIS IS THE 2ND SAFETY ISSUE I HAVE BEEN INVOLVED IN AND LUCKILY NO ACCIDENT HAD OCCURRED. I WILL BE SENDING VEHICLE TO MAINTENANCE SHOP FOR A 2ND TIME TO TRY AND HAVE THIS SAFETY ISSUE REPAIRED, AGAIN. ANY HELP THAT NHTSA CAN DO TO HELP SOLVE THIS SAFETY ISSUE IS GREATLY APPRECIATED. *TR

NHTSA ID

10499639

Incident

Feb 21, 2013

Mileage

4,551 mi

SERVICE BULLETIN M1684: MARKET SPECIFIC BATTERY INTRODUCTION. PURPOSE: Initial Release. This bulletin informs dealers of the availability of new batteries for new Original Equipment (OE) vehicle production and in the Parts and Accessories (P&A) catalog. Availability of the new Absorbed Glass Mat (AGM) batteries will vary by market and will be transitioning over the next few months. NOTE: The ring terminal screws are not compatible between Leoch and East Penn batteries. The new batteries will include new ring terminal screws, which must be used. The ring terminal screws from the old battery need to be discarded.

BUELL MOTORCYCLES: CERTAIN MOTORCYCLES-1125R AND 1125CR 2009-10 AND 2008 1125R HAVE BEEN REFITTED WITH A 2009 OR 2010 ENGINE. ON THESE MODELS THE STATOR MAY OPERATE AT TEMPERATURES THAT EXCEED THE MANUFACTURER'S RECOMMENDATION WHEN THE VEHICLE IS RIDDEN IN LOWER RPM (BELOW 5,000 RPM) DUTY CYCLES. THE MODELS MAY EXPERIENCE CHARGING SYSTEM ISSUES RELATED TO EXCESSIVE STATOR HEAT. *PE UPDATED 6/11/10. *PE

BUELL MOTORCYCLES: MAY EXPERIENCE A PREMATURE FAILURE OF THE REAR CYLINDER CAM CHAIN TENSION GUIDE. THIS CAN CAUSE PLASTIC DEBRIS TO BLOCK THE OIL PUMP SCREEN, POSSIBLY LEADING TO OIL STARVATION AND ENGINE SEIZURE. *PE

BUEL MOTORCYCLES: A DEFECT RELATING TO MOTORCYCLE SAFETY OF CERTAIN 1125CR. MOTORCYCLE MAY EXPERIENCE PREMATURE FAILURE OF THE REAR CYLINDER CAM CHAIN TENSION GUIDE. *PE