2009 Harley-Davidson Flht

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.

TL* THE CONTACT OWNS A 2009 HARLEY-DAVIDSON FLHT ELECTRA GLIDE MOTORCYCLE. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 18V076000 (SERVICE BRAKES, HYDRAULIC). WHILE UNLOADING THE VEHICLE FROM A TRAILER, IT WAS NOTICED THAT THE BRAKES DID NOT WORK. THE VEHICLE WAS TAKEN TO QUEEN CITY HARLEY-DAVIDSON (5960 DIXIE HWY, FAIRFIELD, OH 45014, 513-874-4343) WHERE IT WAS DIAGNOSED THAT THE ABS FAILED AND NEEDED TO BE REPLACED. THE TECHNICIAN STATED THAT THE ABS WAS NOT COVERED BY THE RECALL. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THE ABS WAS NOT COVERED. THE CONTACT CALLED THE STATE ATTORNEY GENERAL AND WAS REFERRED TO NHTSA. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 36,000.

NHTSA ID

11081786

Incident

Mar 16, 2018

Mileage

36,000 mi

TL* THE CONTACT OWNS A 2009 HARLEY-DAVIDSON FLHT ELECTRA GLIDE. WHILE BACKING OUT OF A PARKING SPACE, THE FRONT BRAKES FAILED TO RESPOND. THE MOTORCYCLE WAS TOWED TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE ANTI-BRAKE SYSTEM MODULE FAILED AND NEEDED TO BE REPLACED. THE MOTORCYCLE WAS REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA ACTION NUMBER: PE16009 (SERVICE BRAKES, HYDRAULIC). THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE MOTORCYCLE FAILURE MILEAGE WAS 29,934.

NHTSA ID

10888622

Incident

May 14, 2014

Mileage

29,934 mi

TL* THE CONTACT OWNS A 2009 HARLEY-DAVIDSON FLHT. WHILE DRIVING 60 MPH, THE BRAKES FAILED TO RESPOND WHEN THE BRAKE HANDLE WAS DEPRESSED. THE FAILURE RECURRED INTERMITTENTLY. THE MOTORCYCLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE ANTI-LOCK BRAKE MODULE FAILED AND NEEDED TO BE REPLACED. THE MOTORCYCLE WAS REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VIN WAS UNKNOWN. THE FAILURE MILEAGE WAS 22,000.

NHTSA ID

10883606

Incident

Nov 28, 2015

Mileage

22,000 mi

ANTI-LOCK BRAKES, MOTORCYCLE PURCHASED IN 2009, AT APPR. 12000 MILES, FRONT BRAKE ROTORS WARPED AND HAD TO BE REPLACED. THIS IS AN ISSUE THAT HAS TO BE ADDRESSED AROUND EVERY 12000 MILES SINCE NEW AND I HAVE 90,000 MILES ON IT NOW. AT APPR. 40,000 MILES, THE HOLE FRONT BRAKE SYSTEM HAD TO BE REPLACED, ROTORS, CALIPERS, LINES, MASTER CYLINDER. THE BRAKES WOULD AUTOMATICALLY APPLY THEMSELVES UNTIL I WOULD HAVE TO PULL OVER. THEY WOULD LOCK DOWN. THEY WOULD WORK PROPERLY AFTER I SAT ON SIDE OF ROAD FOR AROUND 30 MINUTES. I TOOK IT TO HARLEY THE NEXT DAY. THE DEALERSHIP TOLD ME THE ROTOR WARPING WAS NORMAL, THAT IS BS. THAT COSTS ME $300 EVERY 1200 MILES. I HAVE HAD TO REPLACE THE REAR ROTOR ONCE, IT NEEDS REPLACING NOW. THE DATE BELOW DON'T REPRESENT ANY ACTUAL TIME.

NHTSA ID

10883517

Incident

May 30, 2009

Mileage

12,000 mi

TL* THE CONTACT OWNS 2009 HARLEY DAVIDSON MOTORCYCLE FLHT. THE CONTACT STATED THAT WHILE DRIVING AT ANY SPEED THE MOTORCYCLE LOST POWER AND THE RPM DROPPED TO 1,000. THE FAILURE OCCURRED INTERMITTENTLY BUT IT BEGAN TO DO SO MORE FREQUENTLY. THE MOTORCYCLE WAS NOT TAKEN TO THE DEALER TO HAVE A DIAGNOSTIC PERFORMED. THE CONTACT BELIEVES THAT THE THROTTLE CONTROL ACTUATOR FAILED. THE MOTORCYCLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 18,000 AND THE CURRENT MILEAGE 23,000.

NHTSA ID

10482185

Incident

Apr 1, 2012

Mileage

18,000 mi

WHILE PULLING AWAY FROM A STOP LIGHT, THE SEAT STARTED TO SLIDE OFF THE REAR FENDER. THE BOTTOM OF THE SEAT IS HARD PLASTIC SOME HOW IT CRACKED ALL THE WAY AROUND THE SEAT MOUNTING BRACKET SO THE SEAT WILL NOT STAY IN PLACE WHEN YOU DRIVE. THE SEAT RETENTION NUT AND THE SEAT BRACKET AND THE FENDER ARE ALL DAMAGED. FROM NORMAL USE. I TALK TO THE DEALER THEY TOLD ME THAT THEY SEE THIS ALL THE TIME. IT SOUNDS LIKE MAYBE HARLEY NEEDS TO FIX THIS PROBLEM BEFORE SOMEONE GETS KILLED... *TR

NHTSA ID

10477353

Incident

Sep 5, 2012

Mileage

25,928 mi

AT AROUND 20,000 MILES I TOOK MY MOTORCYCLE IN TO HAVE THE TIRES CHANGED AND THE REAR WHEEL BEARINGS WERE BAD AND THE DEALERSHIP REPLACE THE REAR WHEEL BEARING. A FEW THOUSAND MILES LATER THE FRONT WHEEL BEARINGS FAILED ON ME IN MONTANA, I AM FROM WASHINGTON STATE, ON THE FREEWAY AND I ALMOST CRASHED, I COULD HAVE DIED RIGHT THERE BUT LUCKILY I WAS NOT IN A TURN AND MANAGED TO GET TO THE SIDE OF THE FREEWAY. A DEALERSHIP IN MONTANA TRAILERED MY MOTORCYCLE IN AND REPLACE THE FRONT WHEEL BEARINGS. NOW AT ABOUT 40,000 MILES I TOOK THE MOTORCYCLE IN TO HAVE THE TIRES REPLACED AGAIN AND THE FRONT AND REAR WHEEL BEARING ARE BAD AGAIN AND BEING REPLACED. MY BROTHER IN LAW HAS A 2004 HARLEY ROAD KING, WITH ALMOST 50,000 MILES, AND HAS NOT HAD ANY PROBLEMS WITH WHEEL BEARINGS. MY YEAR, NOT SURE WHEN HARLEY CHANGED WHEEL BEARINGS, HAVE DIFFERENT WHEEL BEARINGS THAN HIS MOTORCYCLE. THIS IS A MAJOR SAFETY ISSUE, I HAVE READ ON SEVERAL ONLINE FORUMS THAT MANY OTHER PEOPLE ARE HAVING THESE PROBLEMS AND THE MECHANIC AT MY DEALERSHIP HAS TOLD ME THAT MANY PEOPLE HAVE WHEEL BEARING PROBLEMS. PLEASE CRACK DOWN ON HARLEY DAVIDSON ABOUT THIS BEFORE SOMEBODY IS INJURED OR DIES. *TR

NHTSA ID

10476718

Incident

Sep 13, 2010

Mileage

22,000 mi

MY 2009 HARLEY FLHT WAS MAKING A LOUD CLUNKING NOISE AT START-UP. I SEARCHED THE INTERNET AND FOUND MANY OWNERS HAVING A COMPENSATOR BOLT LOOSE FROM FACTORY. I TOOK THE MOTORCYCLE TO BRUCHMHLBACH HARLEY DAVIDSON IN BRUCHMHLBACH GERMANY AND WHEN THEY TOOK THE PRIMARY COVER OFF THEY FOUND THE BOLT TO BE LOOSE FROM THE FACTORY. HAD THE BOLT FALLEN OUT IT WHILE THE MOTORCYCLE WAS IN MOTION IT WOULD HAVE FALLEN INTO THE SPINNING CHAIN BELOW AND LOCKED UP THE BACK WHEEL. THIS COULD HAVE CAUSED ME TO LOSE CONTROL OF THE MOTORCYCLE. NO RECALL HAS BEEN ISSUED FOR THIS PROBLEM. HARLEY DAVIDSON HAS SINCE FIXED THIS PROBLEM ON THE 2011 MODELS BY INSTALLING THE SCREAMING EAGLE COMPENSATOR ON ALL NEW MODELS BUT THE 2009 IS LEFT UNCHANGED. *TR

NHTSA ID

10392310

Incident

Oct 27, 2010

Mileage

3,000 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.