2009 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.

STATOR FAILED IN TRAFFIC ON THE HIGHWAY, HAD TO PUSH BIKE ACROSS A LANE OF TRAFFIC ON HWY 95 FLORIDA.

NHTSA ID

10785876

Incident

Oct 6, 2015

Mileage

7,016 mi

RIDING MY 2009 BUELL 1125R, THE OEM STATOR OVERHEATED AND FRIED 1 LEG OF THE 3 LEG STATOR. I HAD THE HARLEY DAVIDSON RECALL DONE ON THE BIKE AND THIS MADE IT WORSE, WHEN GOING UNDER 5K RPMS THE BIKE WOULD OVERHEAT; WHICH EVENTUALLY LED TO THE STATOR FRYING. THIS CAUSED THE REGULATOR TO BE FRIED AS WELL SINCE THE STATOR GOES DIRECTLY TO THE STATOR. THIS ALSO ALMOST KILLED MY BATTERY. THE HARLEY DAVIDSON FIX DOESN'T WORK AND THEY SHOULD IMPLEMENT A BETTER FIX FOR THE BIKE. *TR

NHTSA ID

10702678

Incident

Mar 30, 2015

Mileage

3,450 mi

VOLTAGE LIGHT CAME ON WITH CHECK ENGINE LIGHT. ENGINE DIED. THIS IS THE THIRD TIME THE STATOR HAS WENT OUT. ONE TIME THE VOLTAGE REGULATOR WENT OUT. HARLEY REFUSED TO FIX IT UNDER WARRANTY. I HAVE 2 OF THESE MOTORCYCLES & BOTH HAVE THE SAME PROBLEMS. *TR

NHTSA ID

10577764

Incident

Apr 30, 2013

Mileage

4,500 mi

TL* THE CONTACT OWNS A 2009 BUELL 1125R. THE CONTACT STATED THAT WHEN THE VEHICLE BECAME HOT AND THE ENGINE FAN WOULD ENGAGE, THE VEHICLE OVERHEATED AND STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DETERMINED THAT THE STATOR AND THE CLUTCH HAD FAILED. THE DEALER REPLACED THE ORIGINAL CLUTCH AND CHANGED THE WIRING HARNESS FROM A 4-CHARGE TO A 3-CHARGE STATOR AND CLUTCH. THE WIRING HARNESS FAILURE ALSO DRAINED THE BATTERY PREMATURELY. THE CONTACT CHANGED THE BATTERY THREE TIMES BEFORE DISCOVERING THE FAILURE. THE DEALER STATED THAT THE MANUFACTURER WAS AWARE OF THE PROBLEM AND HAD THREE DIFFERENT COMPANIES PRODUCING THE WIRING HARNESS AND STATOR FOR THE CLUTCH, BUT THE FAILURE HAD NOT BEEN CORRECTED. THE FAILURE MILEAGE WAS 1,400 AND THE CURRENT MILEAGE WAS 3,509. *TR

NHTSA ID

10510420

Incident

Mar 5, 2012

Mileage

1,400 mi

BIKE HAS HAD MULTIPLE CHARGING ISSUES: STATOR, VOLTAGE REGULATOR, AND OTHER COMPONENTS. CURRENTLY GOING TO REPAIR IN SPRING. *TR

NHTSA ID

10500994

Incident

Jul 11, 2012

Mileage

9,000 mi

WHILE RIDING BUELL 1125R 2009 I EXPERIENCED A COMPLETE POWER FAILURE WHILE RIDING. LOSING POWER IN TRAFFIC IS DANGEROUS. AFTER DOING RESEARCH IT APPEARS THIS IS A VERY WIDESPREAD ISSUE WITH THIS MODEL YEAR BUELL. IT IS DANGEROUS AND COSTLY TO THE CONSUMER AND SHOULD BE RESOLVED BY THE COMPANY. *TR

NHTSA ID

10497949

Incident

Jan 18, 2013

Mileage

5,164 mi

STATOR FAILURE CHARGING SYSTEM FAILED. *TR

NHTSA ID

10497643

Incident

Oct 5, 2011

Mileage

8,370 mi

2009 BUELL 1125R - I BOUGHT IT FROM AN HD DEALERSHIP (LIKE NEW) WITH 2,500 MILES ON IT. THE BIKE HAD NO WARRANTY. THEY TRIED TO SELL ME AN 'EXTENDED WARRANTY' WHICH I DID NOT BUY (FOR ABOUT $2K). THIS WAS EITHER STANDARD PROCEDURE, OR SUSPICIOUS - I DON'T KNOW WHICH, BECAUSE THE BIKE'S CHARGING SYSTEM (STATOR) FAILED ON ME AT 3,586 MILES. FORTUNATELY, I WAS NEARLY HOME. LIKE SOME OF THE OTHER COMPLAINTS, THE ENGINE DIED AMID TRAFFIC (LOW SPEED, THANKFULLY). THE BATTERY & ENGINE LIGHTS CAME ON ABOUT A MILE BEFOREHAND. I HAD THE BIKE DIAGNOSED/REPAIRED (STATOR REPLACEMENT) AT AN HD/BUELL CERTIFIED DEALERSHIP. COST (PARTS & LABOR) $1,045 !!! I HAVE SINCE READ THAT THIS HAS BEEN A HUGE ISSUE ESPECIALLY WITH THE 09 1125R BUELL'S. I HAVE HEARD OF OWNERS THAT ARE CAPABLE OF DOING THEIR OWN MECHANIC WORK, PULLING THE (BAD) STATOR AND ROTOR, AND SENDING THEM TO (EBR) ERIC BUELL RACING - FOR A 'RE-WIND' ON THE STATOR FOR AROUND $150 - TO - $175. EBR ALSO SELLS AN 'UPGRADED' ROTOR FOR $450 THAT SUPPOSEDLY DOES A BETTER JOB OF LUBRICATING THE STATOR, THUS ELIMINATING THE PROBLEM. THIS SHOULD DEFINITELY BE A TOTAL RECALL ! *TR

NHTSA ID

10496957

Incident

Dec 22, 2012

Mileage

3,586 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