2008 Buell 1125R

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.

TL* THE CONTACT OWNS A 2008 BUELL 1125R MOTORCYCLE. THE CONTACT STATED THAT THE VEHICLE WOULD SHAKE VIOLENTLY WHEN COMPLETING A TURN. THE CONTACT WAS DRIVING AN UNKNOWN SPEED WHEN THE REAR WHEEL SEIZED AND THE WHEEL BEARINGS BECAME DETACHED FROM THE VEHICLE. IN ADDITION, THE FRONT FORK SEALS WERE LEAKING. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 21,000.

NHTSA ID

10500807

Incident

Dec 18, 2012

Mileage

21,000 mi

TL* THE CONTACT OWNS A 2008 BUELL MOTORCYCLE 1125R. THE CONTACT STATED THAT THE CLUTCH LEAKED HYDRAULIC FLUID DUE TO A DEFECTIVE LEVER THAT CAUSED THE LEVER NOT TO ENGAGE. THE VEHICLE WAS TAKEN TO THE DEALER WHO REPLACED THE CLUTCH ASSEMBLY. THE VEHICLE WAS REPAIRED. THE MANUFACTURER ADVISED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 08V267000 (POWER TRAIN: CLUTCH ASSEMBLY) THE FAILURE MILEAGE WAS 310 AND THE CURRENT MILEAGE WAS 600. UPDATED 10/18/12*LJ UPDATED 10/25/12

NHTSA ID

10478359

Incident

Sep 20, 2012

Mileage

310 mi

TL* THE CONTACT OWNS A 2008 BUELL 1125R MOTORCYCLE. THE CONTACT STATED THAT WHILE ENTERING THE HIGHWAY AT 55 MPH, THE ENGINE RPM'S INCREASED TO 5000-6000 AS THE VEHICLE ABNORMALLY DECELERATED. IN ADDITION, THE CONTACT STATED THAT WHILE HIS HANDS WERE OVER THE THROTTLE, THE FRONT END OF THE VEHICLE ROSE FROM THE GROUND RAPIDLY, ALMOST THROWING THE CONTACT FROM THE VEHICLE. THE FAILURE WAS RECURRING. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 13,184.

NHTSA ID

10454983

Incident

Apr 10, 2012

Mileage

13,184 mi

I PURCHASED 08 BUELL W/ EXTENDED SERVICE PLAN FROM HARLEY DAVIDSON HAMPTON ROADS. IT BROKE DOWN IN ALABAMA ON 9/3/11. I HAD A BUELL SERVICE CENTER IN ALABAMA LOOK AT THE BIKE & THEY ADVISED ME HDHR DEALERSHIP IS NOT A SERVICE CENTER THAT SPECIALIZES IN BUELL & SAID HDHR OVERSERVICED MY BIKE CAUSING IT TO BREAK DOWN. UPON MY RETURN TO VA, I BROUGHT MY BIKE BACK TO HDHR. I REQUESTED MY $150.00 SERVICING FEE BE RETURNED TO ME. HDHR DECIDED TO FURTHER SERVICE MY BIKE & SAID THEY FOUND PLASTIC IN THE OIL WHICH CAUSED THE OIL LINES TO CLOG & THEY NEEDED TO BREAK DOWN THE ENGINE. THEY SAID THE BIKE WAS VANDALIZED B/C THERE WAS NO OTHER WAY FOR PLASTIC TO CLOG THE LINES. I TOLD THEM MY BIKE WAS NOT VANDALIZED & I NEVER SAW ANY DAMAGE INDICATED IT WAS. THEY SAID THEY NEVER SAW ANY DAMAGE TO SUGGEST VANDALISM EITHER BUT TOLD ME I HAD TO FILE A CLAIM THRU MY INS CO. DESPITE IT WAS ALREADY ON RECORD HDHR OVERSERVICED MY MOTORCYCLE WHICH CREATED A BREAK DOWN, NO EVIDENCE OF VANDALISM, & BUELLS KNOWN ISSUE/RECALL OF PLASTIC PARTICLES IN ENGINES, THEY SAID THE BIKE WAS VANDALIZED & WOULD NOT BE COVERED UNDER MY SERVICE AGREEMENT. MY INSURANCE CO DECLARED THE BIKE A TOTAL LOSS DUE TO THE PARTICLES IN THE ENGINE & BUELL NOT RELEASING ANY ENGINES TO DEALERS UNLESS IT IS A WARRANTY ISSUE. I SPOKE W/ HDHR SERVICE DEPT & FOUND OUT THE ENGINE HAS NOT EVEN BEEN SHIPPED TO ESP & SO ESP HASN'T MADE ANY DETERMINATION BUT HDHR SAYS I NEED TO PAY FOR A NEW ENGINE. SERVICE DEPT ALSO TOLD ME THAT THEY USED THE APRIL 08 OWNERS MANUAL FOR THE INITIAL SERVICING OF MY BIKE (DESPITE MANUAL BEING AMENDED & NEW PROCEDURES IN PLACE FOR PROPER SERVICING IN 08) & THAT THERE WAS NO EVIDENCE AT ALL OF VANDALISM BUT THEY WERE ASSUMING SOMEONE PUT SAND IN THE OIL COMPARTMENT EVEN THO THERE WAS NO EVIDENCE OF SAND SETTLING IN THE OIL COMPARTMENT & PREVIOUS RECORDS SHOW PLASTIC PARTICLES. *TR

NHTSA ID

10432362

Incident

Sep 3, 2011

STATOR FAILURE ALONG WITH A CLUTCH LEAK THAT CAUSED OIL TO GET ON THE BACK TIRE AND CAUSE AN ACCIDENT, BIKE WAS TOTALLED. *TR

NHTSA ID

10430176

Incident

Sep 25, 2010

Mileage

4,000 mi

2008 BUELL 1125R CLUTCH FLUID LEAKS OUT WEEP HOLE AND CAUSES THE LOSS OF CLUTCH WHICH MAKES CONTROL OF BIKE DANGEROUS, HARLEY HAS HAD THIS PROBLEM AND KNOWS ABOUT IT AND HAS AT THIS TIME DONE NOTHING TO FIX, IF BIKE IS UNDER WARRANTY THEY FIX IT , IF OUT OF WARRANTY THEY DO NOTHING TO PROTECT YOUR SAFETY. *TR

NHTSA ID

10349918

Incident

Aug 14, 2010

Mileage

1,060 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 MOTORCYCLE: MOTORCYCLES HAVE A FRONT BRAKE LINE WHICH MAY CONTACT THE FRONT TIRE. THE CONDITION COULD CAUSE A HOLE TO DEVELOP IN THE FRONT BRAKE LINE, ALLOWING BRAKE FLUID TO LEAK. MODELS 1125R, XB12R, XB12SCG. *PE

BUELL MOTORCYCLES: MOTORCYCLES EQUIPPED WITH CALIFORNIA EVAPORATIVE EMISSIONS COMPONENTS DO NOT REQUIRE THE VENT LINE UPGRADE PROCEDURE. SIDESTAND SPRING/OIL FILLER PLUG INSPECTIONS/REPLACEMENT ARE THE ONLY PROCEDURES THAT SHOULD BE PERFORMED. *PE

BUELL MOTORCYCLE: A CONDITION AFFECTING MOTOR VEHICLE SAFETY EXISTS ON CERTAIN 2008 1125R MOTORCYCLES. MOTORCYCLE CAN EXPERIENCE 5TH GEAR GALLING ON THE CLUTCH SHAFT DUE TO LACK OF LUBRICATION. *PE