2008 Harley-Davidson Flhtc

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.

THE SUBJECT FUEL FILTER HOUSING (P/N 62229-08) CRACKS, RESULTING IN SUDDEN ENGINE STALL DUE TO UNREGULATED FUEL PRESSURE.HARLEY-DAVIDSON HAS MODIFIED THE HOUSING WITH A NEW PART NUMBER 62229-08A.SHORTLY AFTER OPENING THIS PE, ODI RECEIVED HARLEY'S DEFECT NOTIFICATION INDICATING THAT THE SUBJECT VEHICLES WERE BEING RECALLED TO INSTALL THE NEW FUEL FILTER HOUSING.WITH THAT RECALL, RECEIVED PRIOR TO RELEASE OF OUR INFORMATION REQUEST, THIS INVESTIGATION IS CONCLUDED.

I WOULD LIKE TO BRING TO LIGHT AN ISSUE I HAVE RECENTLY HAD FOUND. I RIDE A 2008 HARLEY DAVIDSON ELECTRAGLIDE. I ONLY HAVE 42000 MILES ON IT. LAST FALL I WAS COMING BACK FROM A MEMORIAL MISSION WITH THE AMERICAN LEGION RIDERS. I NOTICED A STRANGE RATTLE IN MY PRIMARY CASE AREA. I GOT HOME AND PARKED IT UNTIL I COULD OPEN IT UP TO SEE WHAT THE ISSUE IS. A FEW WEEKS LATER I FINALLY WAS ABLE TO OPEN UP THE PRIMARY CASE. WHAT I FOUND WAS 2 LARGE PIECES OF METAL LOOSE IN THE PRIMARY CASE. THIS IS WHERE THE CLUTCH, DRIVE CHAIN, COMPENSATOR, AND STATOR ARE. IMMEDIATELY I WAS SCARED AND THANKFUL THAT ONE OF THOSE PIECES DIDN'T GET STUCK IN THE DRIVE CHAIN AND SPROCKET. IF IT HAD WHEN I WAS GOING DOWN THE ROAD IT WOULD HAVE LOCKED UP THE REAR WHEEL IMMEDIATELY AND I WOULD NOT BE HERE. I FINALLY WAS ABLE TO DETERMINE THE PIECES CAME OFF THE COMPENSATOR. I BEGAN SEARCHING THE INTERNET TO SEE IF THIS WAS COMMON. TO MY SURPRISE IT IS COMMON AND HARLEY DAVIDSON CORPORATE KNEW ABOUT THE FLAWED DESIGN AND DID NOT DO A RECALL OR INFORM OWNERS OF THE ISSUE. I CONTACTED SALEM HARLEY DAVIDSON AND THEY PUT ME IN TOUCH WITH HARLEY DAVIDSON CUSTOMER CARE. WHEN I TALKED TO THEM I FOUND THEY KNEW OF THE ISSUE AND CHANGED THE DESIGN IN 2012. I WAS TRYING TO GET THEM TO FIX MY BIKE BUT THEY REFUSED SAYING IT WAS OUT OF WARRANTY. GRANTED IT IS BUT THIS WAS A KNOWN ISSUE AND OWNERS SHOULD HAVE BEEN NOTIFIED. ONE OF THE MAIN REASONS FOR CONTACTING YOU IS TO HOPEFULLY MAKE PEOPLE AWARE OF THE PROBLEM. I CAN'T HELP TO WONDER HOW MANY MOTORCYCLE RIDERS HAVE LOST THEIR LIVES DUE TO THE SAME THING HAPPENING TO THEM. EXCEPT THEY WEREN'T AS FORTUNATE AS I WAS. AS I SAID BEFORE IF 1 OF THOSE PIECES GOT STUCK IN THE PRIMARY CHAIN WHILE GOING DOWN THE ROAD IT WOULD BE CATASTROPHIC. UNFORTUNATELY THE ACTUAL CAUSE MAY NOT BE FOUND BECAUSE OF THE EXTENSIVE DAMAGE.

NHTSA ID

11066699

Incident

Sep 25, 2017

Mileage

42,000 mi

ON 10-19-2017 I WAS RIDING WITH A GROUP OF FRIENDS ON OUR WAY TO A FELLOW BIKERS FUNERAL. WE WERE DOING ABOUT 45 MPH ON THE HIGHWAY, AS WE APPROACHED OUR TURN I ATTEMPTED TO START BRAKING WITH MY BACK BRAKE. WHEN I TRYED TO PUSH THE BACK BRAKE PEDAL DOWN NOTHING HAPPENED!!!!!!!!!!! THE PEDAL WAS FROZEN IN PLACE!!!!!!!!! I BROUGHT THE BIKE TO A FRIENDS AND HE AND I STARTED TO LOOK INTO THE PROBLEM. WHEN WE GOT TO THE ABS BRAKE MANIFOLD, WE FOUND THAT WHEN WE CRACKED THE INLET LINE THE BACK BRAKE PEDAL WOULD GO DOWN AND PUSH FLUID OUT. WE TIGHTENED THE INLET LINE BACK AND BROKE LOOSE THE OUTLET LINE AND THE BACK BRAKE PEDAL WOULD NOT MOVE AGAIN. ON 11-1-2017 I SPOKE TO THE DEALERSHIP I BOUGHT THE BIKE FROM ( MIKE BRUNO'S HOUMA LOUISIANA) AND TOLD THEM WHAT HAPPENED. THEIR RESONSE WAS ...DO YOU HAVE THE EXTENDED WARRANTY? I TOLD THEM NO, SO THEY TOLD ME THE PART WILL COST $417.00. THANK GOD I DID NOT HAVE A PASSENGER WITH ME OR DID NOT HIT THE BIKE IN FRONT OF ME. THERE WAS ZERO WARNING BEFORE THIS FAILURE NO LIGHTS NO TIGHTING OF BRAKE PEDAL NOTHING!!!!!!!!!! I GUESS MY LIFE AND OTHERS IS ONLY WORTH $417.00 AND THAT IS ONLY IF I BUY THE NEW PART AND IT DON'T FAIL ALSO.

NHTSA ID

11042028

Incident

Oct 19, 2017

Mileage

3 mi

I TOOK MY BIKE OUT FOR A NICE RIDE AND NOTHING IN THE WAY OF A PROBLEM. THE NEXT DAY WENT TO RIDE THE BIKE AND MY FRONT BRAKE LEVER IS AS HARD AS A ROCK I WENT TO STOP AND HAD NO FRONT BRAKE. WENT THROUGH THE INTERSECTION . I CHECKED FOR TROUBLE CODES IN THE MEMORY AND IT SHOWED NONE. TRIED TO BLEED THE FRONT BRAKES CRACKED THE BLEEDER AND LEVER MOVED FINE AND FLUID CAME OUT AS NORMAL . TRIED TO USE BRAKE AND LEVER WAS HARD AGAIN. CALL THE LOCAL DEALER AND WAS INFORMED THE ABS MODULE WAS BAD AND IT WOULD COST A 1000.00 . I WAS UNDER THE IMPRESSION THAT IF THE SYSTEM FAILED IT WOULD JUST REVERT BACK TO BRAKES WITH OUT ABS.AM I WRONG ABOUT THE WAY THEY SHOULD WORK INFORMED BY SERVICE WRITER THAT THEY COULD LOCK UP OR HAVE NO BRAKES AT ALL . I THINK THEY SHOULD TAKE A LITTLE MORE OF EFFORT TO FIND OUT WHAT THE PROBLEM RATHER THAN JUST COME UP WITH THE FIGURE OF 1000 AND SAY THE MODULE IS BAD . MAKES ME THINK THAT I AM NOT THE FIRST PERSON THAT THIS HAS HAPPENED TO. SAID HARLEY WOULD COVER BUT I INFORMED HIM IT RAN OUT 6 MONTHS AGO. BY THE WAY I BOUGHT THE BIKE NEW. THANK YOU [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10936640

Incident

Oct 15, 2016

Mileage

17,500 mi

I RECENTLY WAS RIDING WHEN THE FRONT BRAKE HANDLE ON THE BIKE STARTED TO VIBRATE. I WAS CLOSE TO HOME SO I WENT THERE. SINCE IT WAS TIME TO DO SOME MAINTENANCE ON THE BIKE I ORDERED PARTS AND OVER THE NEXT COUPLE OF MONTHS CHANGED FLUIDS AND DID OTHER ITEMS INCLUDING REPLACING THE FRONT RIGHT HANDGRIP. AFTER REPAIRS WERE COMPLETE I STARTED THE BIKE AND DID A TEST RIDE A FEW 100 METERS DOWN MY STREET AND WHEN I WENT TO USE THE BRAKES THE FRONT BRAKE HANDLE WAS FROZEN. I ALSO NOTICED THAT THE REAR BRAKE WAS FEELING VERY STIFF. I REMOVED THE FRONT BRAKE FLUID COVER AND INSPECTION THE MASTER CYLINDER, CLEANS THE COVER AND REPLACED WITH THE SAME ISSUE OCCURRING. I THOUGHT MAYBE THERE WAS AN ISSUE WITH FLUID REACHING THE FRONT CALIPER AND INSPECTED THE BLEEDERS WHICH I OPENED SLIGHTLY WITH NO FLUID BEING ABLE TO REACH THE CALIPERS. AT THIS TIME I DECIDED THAT THIS WAS BEYOND MY ABILITY TO SAFELY REPAIR AND SINCE THE BIKE NEEDED TIRES I TRAILERED THE BIKE TO THE DEALER. WHEN I REACHED THE DEALER I STARTED THE BIKE AND ATTEMPTED TO BACK THE BIKE DOWN AND AT THAT TIME THE REAR BRAKE FAILED COMPLETELY. I INFORMED THE DEALER OF THIS AND THE FRONT BRAKE BEING FROZEN. THE DEALER THEN TOLD ME THAT BOTH MASTER CYLINDERS NEEDED TO BE REBUILT. NO MENTION OF ANY NOTICE FROM HARLEY WAS MENTIONED. THE DEALER HAD NUMEROUS ISSUES GETTING THE PARTS FOR THE MASTER CYLINDERS AND THE BIKE SAT FOR OVER A MONTH. THEY FINALLY RECEIVED THE PARTS AND TOLD ME THE BIKE WOULD BE READY ON THE AFTERNOON OF THAT DAY. WHEN I WENT TO GET THE BIKE THEY INFORMED ME THAT THE ABS HAD FAILED AND THEY WAS A NEW PART FROM HARLEY DAVIDSON THAT WAS REPLACING THE OLD ABS CONTROLLER AND THAT IS WAS ON BACK-ORDER. I THEN CALLED HARLEY DAVIDSON DIRECTLY AND AS SOON AS THE HEARD THE MAKE AND MODEL OF THE BIKE THE CUSTOMER SERVICE PERSON SAID "YES SIR THERE IS AN ISSUE WITH THE ABS CONTROLLER

NHTSA ID

10906432

Incident

Jul 30, 2016

Mileage

8,790 mi

COMPENSATOR IN PRIMARY WENT OUT WITH ONLY 25,000 MILES. UPON RESEARCH, IT IS FOUND THAT THIS IS A KNOWN PROBLEM TO HARLEY, YET THEY HAVEN'T SAID ANYTHING. THIS IS A MAJOR COST TO THE CONSUMER AND MOST IMPORTANTLY DANGEROUS!!! IF THIS GOES OUT WHILE YOU ARE RIDING DOWN THE HIGHWAY, IT LOCKS THE BACK WHEEL AND PRIMARY ENGINE! NO TELLING HOW MANY DEATHS HAPPENED WITH THIS AND IT'S GOES WITHOUT ANYTHING BEING SAID. THERE SHOULD BE AN IMMEDIATE RECALL BEFORE MORE DEATHS OCCUR. THANK GOD MY MECHANIC FOUND THIS WHILE FIXING ANOTHER UNRELATED PROBLEM. HARLEY SHOULD RECALL AND FIX ASAP WITHOUT COST TO US CONSUMERS! BRYAN, TX

NHTSA ID

10885670

Incident

Jul 11, 2016

Mileage

25,000 mi

FRONT BRAKES FAILED COMPLETELY. BRAKE LEVER BECAME ROCK HARD & WOULD NOT ACTIVATE THE FRONT BRAKES AT ALL. THIS OCCURRED WHEN ATTEMPTING TO USE VEHICLE AFTER IT HAD BENEFITTING A FEW DAYS. VERY SHOCKED WHEN I WENT TO USE THE FRONT BRAKES & THEY WOULD NOT WORK, ALMOST CAUSING AN ACCIDENT.

NHTSA ID

10862470

Incident

Apr 1, 2016

Mileage

14,000 mi

MET FRIENDS AT QUAKER STEAK FOR A RIDE,STARTED BIKE,RAN FOR 10 SECONDS THEN DIED,FUEL FILTER HOUSING CRACKED,WAS TOLD THERE WAS A RECALL ON THIS BUT DEALER STATED WAS NOT PART OF THE RECALL,TO ME IT SHOULD BE,HAD TO BE TOWED AND THEN 52.00 IN PARTS WITH ME FIXIG MYSELF

NHTSA ID

10758755

Incident

Aug 14, 2015

Mileage

68,348 mi

DRIVING MY HARLEY AT ABOUT 20-30 MPH PULLING UP TO RED LIGHT. GO TO HIT FRONT BRAKE. NOTHING. FRONT BRAKE IS COMPLETELY DISABLED WITHOUT ANY WARNING. IT APPEARS THAT HARLEY DAVIDSON HAS FAULTY ABS MODULES AND THIS IS NOT THE FIRST NOR PROBABLY THE LAST OF THIS ISSUE. THANK YOU FOR TAKING THE TIME TO READ MY COMPLAINT. *TR

NHTSA ID

10584542

Incident

Apr 23, 2014

Mileage

55,005 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.