2009 Harley-Davidson Flhr

The Office of Defects Investigation (ODI) opened this investigation in July 2016 based on forty-three (43) Vehicle Owner Questionnaires (VOQ).During the course of this investigation ODI received a total of 145 VOQs related to the alleged defect on the subject motorcycles.Owners allege they experience a sudden and complete loss of brakes on one or both wheels.To better understand the cause of the braking issue on the subject motorcycles, ODI requested NHTSA's Vehicle Research and Test Center (VRTC) conduct inspections and testing of affected vehicle braking systems.Through its work, VRTC determined that deposits were forming on the valves in the Hydraulic Control Unit (HCU) of the Antilock Braking System (ABS). These deposits could prevent the proper function of the HCU and render the brakes ineffective.To understand why deposits were forming in the HCU, Harley Davidson completed an analysis of the Dow 460 brake fluid used as original equipment on the subject motorcycles and determined that it had stability issues if left in the brake system for an extended period of time.Harley Davidson found that if a brake fluid flush was not conducted as outlined in the owner?s manual for the motorcycles, and was left in the system for a period of time beyond their recommendation; deposits could form in the HCU.Through further testing, Harley Davidson identified an alternate, commercially available, brake fluid that did not have the same stability issues as the original fluid and could stop the proliferation of any current brake system deposits.ODI sent Information Request (IR) letters to Harley Davidson and Dow Chemical (the supplier of the brake fluid on the subject motorcycles) to collect information about the subject bikes and the alleged defect.Harley Davidson responded in full on Sept 30, 2016 and Dow responded with a confidential submission on October 25, 2017.ODI analyzed the information contained in both IR responses and concluded that motorcycles manufactured during Model Years (MY) 2008, 2009, 2010, and 2011 were failing at a rate greater than their peers.Based on this analysis and the brake fluid study conducted by Harley Davidson, a group of motorcycles was identified that were potentially affected by the instability of the original brake fluid.2008 marked the introduction of ABS on Harley Davidson motorcycles and a change in the Dow 460 brake fluid used in the 2012 MY vehicles provided the bases for the scope of the affected population.With recall action 18V-076 taken by Harley Davidson this investigation is closed as further use of agency resources does not appear to be warranted.The ODI reports cited above can be reviewed at: https://www.nhtsa.gov/ using the complaint identification numbers attached to this resume.

ABS MODULE IS BAD. IT'S A REGULAR PROBLEM WITH HARLEY DAVIDSON. IF YOU LOOK AT FORUMS YOU CAN SEE A LOT OF PEOPLE WHO HAVE HAD THE SAME PROBLEM. I HAD JUST STARTED MY MOTORCYCLE PULLED OUT IN TO TRAFFIC. THEN TRIED TO USE MY FRONT BRAKES, AND WAS UNABLE TO SQUEEZE BRAKE LEVER. I HAD JUST RODE MY MOTORCYCLE THE NIGHT BEFORE. WITH NO PROBLEMS. LUCKILY I WAS ABLE TO USE MY REAR BRAKES. THIS IS EXTREMELY UNSAFE!!! I THOUGHT IT MIGHT BE A PROBLEM FOR ONLY A FEW. BUT LOOKING UP THE PART, I FOUND OUT DIFFERENT. HARLEY DAVIDSON CHARGES A LOT OF MONEY FOR THEIR MOTORCYCLES. AND THEY SHOULD MAKE THEM SAFE.

NHTSA ID

11048463

Incident

Oct 25, 2017

COMPENSATOR FAILURE

NHTSA ID

10894042

Incident

Aug 8, 2016

Mileage

1 mi

NO FRONT BRAKE. UNABLE TO APPLY FRONT BRAKE. FRONT BRAKE FROZEN. MOTORCYCLE TAKEN TO HARLEY DEALERSHIP FOR REPAIR, ABS HCU REPLACED.

NHTSA ID

10887659

Incident

Jun 29, 2013

Mileage

19,851 mi

TL* THE CONTACT OWNS A 2009 HARLEY DAVIDSON FLHR. THE CONTACT STATED THAT THE FRONT BRAKE FAILED TO ENGAGE WHILE ATTEMPTING TO COME TO A COMPLETE STOP. AS A RESULT, THE CONTACT DROVE THROUGH THE INTERSECTION. THE CONTACT INSPECTED THE MOTORCYCLE AND FOUND THAT THE ABS MODULE INTERLOCK BRAKE SYSTEM FAILED. THE CONTACT DISCONNECTED THE ABS FUSE. THE MOTORCYCLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 19,000. UPDATED 5/12/15*CN UPDATED 10/2/2017*CN

NHTSA ID

10701606

Incident

Mar 1, 2015

Mileage

19,000 mi

I WAS EXITING THE FREEWAY AT 55MPH WHEN I SLIGHTLY BANKED RIGHT, THE ENGINE DIED. I COASTED TO THE SIDE, TURNED THE IGNITION SWITCH OFF, THEN BACK ON AND IT STARTED AND RAN PERFECTLY. THE ENGINE DIED AGAIN WHILE ENTERING THE FREEWAY AT A LATER TIME. AGAIN, I WAS BANKING TO THE RIGHT ON A SWEEPING TURN. THE BIKE STARTED AS BEFORE AFTER COASTING TO SIDE OF THE ONRAMP. I RODE WITHOUT A PROBLEM UNTIL I ENTERED THE FREEWAY AT THE SAME ON RAMP A FEW HOURS LATER. THE ENGINE DIED IN THE SAME EXACT PLACE. THIS IS A DANGEROUS SITUATION! *TR

NHTSA ID

10643722

Incident

Oct 7, 2014

Mileage

28,540 mi

SEVERAL TIMES OVER THE PAST 2 YEARS I HAVE LOST ABILITY TO CONTROL MY THROTTLE. THROTTLE POSITION CLOSES AND DOES NOT ACCEPT INPUTS FROM THE ACCELERATOR. SEVERAL TIMES WHILE TRAVELING ON THE EXPRESSWAY THE THROTTLE HAS SHUT AND THE MOTORCYCLE WENT INTO 'LIMP HOME' MODE. THIS WILL ONLY ALLOW A SPEED OF APPROXIMATELY 10-15MPH (DANGEROUS WHILE TRAVELING AT HIGH RATES OF SPEED). THE CONCERN IS WELL KNOW BY THE HARLEY DAVIDSON COMPANY. THEY HAVE EVEN ISSUED A TECHNICAL TIP BULLETIN (#TT418A) ON THE SUBJECT. HOWEVER, NO VOLUNTARY OR REQUIRED SAFETY RECALLS HAVE BEEN ISSUED FOR THIS CONCERN. THIS IS A SAFETY CONCERN: TRAVELING ON THE EXPRESSWAY A SUDDEN LOSS OF ACCELERATION MAY MAKE IT IMPOSSIBLE TO MANEUVER TO THE SHOULDER. LOSS OF ACCELERATION WHILE MAKING A LEFT HAND TURN IN FRONT OF TRAFFIC COULD CAUSE INJURY OR DEATH. *TR

NHTSA ID

10611249

Incident

Jun 18, 2014

Mileage

30,000 mi

PULLED UP TO A STOPLIGHT EVERYTHING WAS FINE, WENT TO PULL AWAY AFTER LIGHT CHANGED BIKE LOST POWER FELT LIKE IT WAS RUNNING ON ONE CYLINDER AND WOULD NOT ACCELERATE. MANAGED TO GET OUT OF TRAFFIC WITHOUT GETTING HIT SHUT BIKE OFF THEN RESTARTED THE BIKE AND ACCELERATION RETURNED TO NORMAL. CHECKED FOR CODES AND HAD A P2135 THROTTLE POSITION SENSOR CLEARED CODES AND HAS NOT RETURNED AS OF YET BUT GETTING READY TO TAKE A TRIP AND DON'T TRUST THIS BIKE.... *TR

NHTSA ID

10523838

Incident

Jun 25, 2013

Mileage

13,758 mi

BIKE GOES INTO LIMP MODE, IDLE ONLY, NO THROTTLE RESPONSE,WHILE DRIVING DOWN THE ROAD. THE FIRST TIME I WAS GOING 60 MPH IN TRAFFIC AND ALMOST GOT RAN OVER. IT HAS HAPPENED SEVERAL TIMES SINCE, AND A FEW AT 70 PLUS MPH. FORTUNATELY I WAS ABLE TO GET OFF THE ROAD WITHOUT A PROBLEM. BUT I WERE TO BE PASSING IN TRAFFIC OR HUNG IN THE CENTER LANE. IT COULD BE TRAGIC. THE FIRST TIME I TOOK IT TO THE DEALER , THE SERVICE MANAGER ACTED AS IF HE NEVER HEARD OF THE PROBLEM. WHEN I TOLD HIM THAT IT IS EASY TO FIND INFO ON THE INTERNET, INCLUDING A HARLEY TECH TIP, TT 418, HE STARTED CHANGING HIS STORY. THEY TOOK IT IN, AND CHARGED ME, TO REPLACE PINS ON THE THROTTLE CONTROL ACTUATOR. NOW 6000 MILES LATER IT IS DOING AGAIN. THE FIRST TIME AT 75 MPH ON THE HIGHWAY, AND THE SECOND TIME AT 70 MPH. IT HAS HAPPENED AT LEAST 10 TIMES IN ALL. THIS IS A SERIOUS SAFETY ISSUE THAT IS FAIRLY COMMON AND KNOW TO HARLEY DAVIDSON. BUT THE DEALER, AND COMPANY, ACTS AS IF IT IS AN UNKNOWN. SOMETHING NEEDS TO DONE TO PREVENT A TRAGEDY, BUT PROBABLY ALREADY HAS, DEAD BIKERS CAN'T TELL WHAT HAPPENED. *TR

NHTSA ID

10520570

Incident

Jun 18, 2011

Mileage

14,000 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.

SERVICE BULLETIN M1650: MILWAUKEE EIGHT AND TWIN CAM CAMSHAFT DRIVE GEAR RETENTION KIT CHANGES. PURPOSE: This bulletin informs dealers that changes have been made to the Camshaft Drive Gear Retention Kit and service proceduresfor the Milwaukee-Eight and Twin Cam applications. In an effort to increase the clamp load of the camshaft drive sprocket bolted joint and prevent the drive bolt from loosening in high lift camshaft applications, the following changes have been made: a. The camshaft drive bolt final torque has been increased to 40 ft-lbs (54 N·m) for all Milwaukee-Eight and certain Twin Cams models. See Vehicles Affected. This increase in torque will make the bolt a one time use application. Never re-use a camshaft drive bolt for service after tightening to the increased specification. See service manual for updated procedure. b. A new camshaft drive gear retention kit (Part No. 91800088) has been created. This new kit is compatible with all Milwaukee-Eight and Twin Cam engines using Parts and Accessories (P&A) camshaft and Original Equipment (OE) camshaft applications. See Instruction sheet for specific fitment on Twin Cam OE camshaft applications. The new kit utilizes friction washers to prevent unwanted rotation of components in the drive sprocket bolted joint under stress. The use of liquid threadlocker on the threads of the bolt and pre-lube to the head of the bolt flange and outside of the washer help the bolt reach full stretch when tightening. NOTE: Engines produced at all Harley-Davidson Motor Company (HDMC) plants will not come with the new kits installed. They will continue to be produced with (Part No. 25566-06).

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.

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.

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.

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.