RoadVitals

2002 Harley-Davidson Flhpi

Recalls, owner-reported complaints, investigations and safety data

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
1
Latest Aug 3, 2004
Safety recallsA safety recall is issued when a manufacturer or NHTSA determines that a vehicle has a safety-related defect or does not comply with a federal motor vehicle safety standard. Recall repairs are free. Whether a specific vehicle is covered depends on its VIN — a recall listed for a model year does not necessarily apply to every vehicle of that year.
2
Latest Mar 18, 2004
InvestigationsNHTSA opens an investigation to examine whether a safety defect may exist. An open investigation is not a determination that a defect exists, and many investigations close without a recall. Investigations can, however, lead to one.
0
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
0

Overview

Our database contains 1 NHTSA owner-reported complaint for the 2002 Harley-Davidson Flhpi, most frequently naming the fuel system category. 2 safety recalls have been issued covering this model year; and 7 manufacturer communications are on file.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

What owners report

Complaints grouped by the component NHTSA recorded

  • Fuel system1100.0%

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Safety recalls

2 campaigns cover this model year

Recalls apply to specific vehicles, not to every vehicle of a model year. Check your VIN with NHTSA or your manufacturer's dealer to confirm whether a recall affects your vehicle.

Check a VIN on NHTSA.gov
04V134000

ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS

Mar 18, 2004
81,496 units potentially affected
The defect: ON CERTAIN TOURING AND POLICE MODEL MOTORCYCLES, THE 40 AMP MAIN CIRCUIT BREAKER CAN "OPEN" FOR REASONS OTHER THAN WHICH IT WAS DESIGNED, CAUSING AN UNEXPECTED INTERRUPTION OF ALL ELECTRICAL POWER TO THE MOTORCYCLE.
The risk: THIS CONDITION COULD CAUSE THE MOTORCYCLE TO STALL, WHICH COULD RESULT IN A CRASH.
The remedy: DEALERS WILL REPLACE THE CIRCUIT BREAKER. OWNER NOTIFICATION BEGAN APRIL 23, 2004. OWNERS SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-343-4056.
HARLEY-DAVIDSON MOTOR COMPANYManufacturer number 0113View on NHTSA.gov
02V002000

EXTERIOR LIGHTING

Jan 4, 2002
28,949 units potentially affected
The defect: ON CERTAIN MOTORCYCLES, THE CLIPS THAT RETAIN THE WIRING FOR THE FRONT FENDER TIP LIGHT CAN BECOME DETACHED FROM THE FENDER, CAUSING THE WIRES TO FRAY AND SHORT.
The risk: THIS COULD CAUSE THE LIGHTING SYSTEM FUSE TO BLOW, LEAVING THE VEHICLE WITHOUT AN OPERATIONAL FRONT FENDER TIP LIGHT, HEADLIGHT, TAILLIGHT, RUNNING LIGHTS, AND PASSING LAMPS (IF EQUIPPED).
The remedy: DEALERS WILL REPLACE THE FENDER TIP LIGHT WIRING HARNESS RETENTION CLIPS, AND INSPECT AND REPLACE, IF NECESSARY, ANY DAMAGED WIRING HARNESSES. OWNER NOTIFICATION BEGAN JANUARY 9, 2002. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT HARLEY-DAVIDSON AT 1-414-342-4680.
HARLEY-DAVIDSON MOTOR COMPANYView on NHTSA.gov

Recent owner complaints

Reports submitted to NHTSA, shown in the owner's own words

Fuel system
Filed Aug 3, 2004

WHILE OPERATING MY MOTORCYCLE, THE ENGINE BEGAN SPUTTERING AND THE ODOR OF GASOINE FUMES BECAME OVERWHELMING. I LOOKED DOWN AT THE AIR INTAKE AND NOTICED GASOLINE SPRAYING ON THE ENGINE AND PAST THE AIR INTAKE. IT WAS QUITE FORTUNATE THAT THIS DID NOT RESULT IN A FIRE! THE FUEL LINE HAD SEPARATED FROM THE CONNECTOR ON THE FUEL RAIL AND THE FUEL PUMP WAS SUPPLYING FUEL AT THE FULL DELIVERY RATE. INSPECTION OF THE FUEL LINE SHOWED THAT THE FUEL LINE WAS A HARDENED PLASTIC LINE (COVERED BY A PLASTIC CORREGATED HEAT SHIELD) THAT WAS HELD IN PLACE BY FRICTION ONLY, THERE WERE NO CLAMPS USED. BECAUSE THE FUEL LINE WAS A HARDENED MATERIAL, WITHOUT ELASTICITY OR RETAINING HARDWARE, THE VIBRATION OF THE ENGINE (AND MOST LIKELY THE HEAT AS WELL) DETERIORATED THE ADHESION OF THE CONNECTION RESULTING IN THE SEPARATION. THIS WAS A USED MOTORCYCLE, BUT IT ONLY HAD 638 MILES AND NO EVIDENCE OR RECORD OF MAINTENANCE IN THIS AREA. THE PROBLEM WAS FIXED BY THE DEALER USING HARLEY-DAVIDSON'S PART LIST WHICH INDICATED 1/4" RUBBER FUEL LINE PROTECTED BY A CORREGATED PLASTIC COVERING FOR HEAT ISOLATION, AND TWO CRIMPED HOSE CLAMPS FOR RETENTION, ONE ON EACH END. I HAVE THE ORIGINAL FUEL LINE FOR INSPECTION.*AK

NHTSA ID
10086100
Incident
Jul 16, 2004
Mileage
723 mi

Manufacturer communications

A bulletin sent by a manufacturer to its dealers. Not a recall, and repairs are not necessarily free.

M1684

ELECTRICAL SYSTEM

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.

M1555

ELECTRICAL SYSTEM

SERVICE BULLETIN M1555 (REV E): BATTERY WARRANTY GUIDELINES. PURPOSE: Revision E. Added: Added procedures for the DCA-8000 E Battery Tester.* Updated: All sections. This bulletin informs the dealership network that Harley-Davidson has provided guidelines for battery warranty.

M1490

ELECTRICAL SYSTEM

SERVICE BULLETIN M1490 (V 24.8.8): DIGITAL TECHNICIAN II - UPDATES AND RELEASE NOTES. PURPOSE: This bulletin informs dealers that Harley-Davidson has made a software update to Digital Technician II (DT II). DIGITAL TECHNICIAN II (PART NUMBER: HD-48650). Version 24.8.8. Release Date: Week of August 5, 2024. New Features for Harley-Davidson vehicles: Advanced Module Replace for 2021 and later Revolution Max; 2023 and later CVO Touring; and 2024 Street Glide (FLHX), Road Glide (FLTRX). New Features for LiveWire vehicles: Updated calibrations for 2024 S2DM EV1/ EV6; 2024 S2MH EV1; and 2024 S2DM, S2MH. Changes: Added Hand Control Module (HCM) (Part No. 71500522A and 71500536A) for reflash support.

PAB1158

ENGINE; POWER TRAIN

GENUINE MOTOR PARTS AND MOTOR ACCESSORIES BULLETIN PAB1158: OIL FILTER PACKAGING AND CASE QUANTITY UPDATE. PURPOSE: To inform dealerships that Harley-Davidson has made updates to oil filters including new part numbers, packaging design, and bulk case quantity changes.

M1490

ELECTRICAL SYSTEM

SERVICE BULLETIN M1490 (V 24.6.4): DIGITAL TECHNICIAN II - UPDATES AND RELEASE NOTES. PURPOSE: Revision. This bulletin informs dealers that Harley-Davidson has made a software update to Digital Technician II (DT II). DIGITAL TECHNICIAN II (PART NUMBER: HD-48650). Version 24.6.4. Release Date: Week of May 1, 2024. New Features for LiveWire S2DM and S2MH, 2024 Revolution® Max, and 2024 Touring.

PAB1146

EXTERIOR LIGHTING

GENUINE MOTOR PARTS AND MOTOR ACCESSORIES BULLETIN PAB1146: 68193-95 BULB WEDGE, FENDER TIP LAMP. Purpose: To inform dealers of an issue with the bulb wire terminals not being to specification. The light bulbs were used in numerous front and rear fender tip light assemblies for domestic and international applications.

Manufacturers file copies of the bulletins they send to dealers with NHTSA. These often describe diagnostic or repair procedures for a known condition. They are not recalls: repairs described in a bulletin are usually only free if the vehicle is still under warranty or the manufacturer has extended coverage.

Compare model years

Complaint and recall counts across every year of this model

Harley-Davidson Flhpi by model year
YearComplaintsRecallsInvestigationsIssue Index
2007010—
2006010—
2005120—
2004100—
2003220—
2002Viewing120—
2001420—
2000310—
1999220—
1998000—
1997000—

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers. Older model years have had longer for reports to accumulate.