2009 Harley-Davidson Flhtcu

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.

While riding my 2009 ultra classic cvc Harley davidson motorcycle the front brake level became stiff and eventually did not compress, no front brakes, while attempting to stop. The rear brake still operated normally. In an emergency, this could cause serious injury or death with front brake failing and possible rear brake failure at same time. a local repair shop inspected the brakes and attempted to bleed system and determined the ABS mudule failed. there were no warning lamp indications of ABS failure. When ABS module fails on HD motorcycles, brakes can also fail. This is a major safety issue with the braking system that shoud still operate to stop motorcycle when ABS module fails.

NHTSA ID

11725017

Incident

Feb 7, 2026

ABS Module failure. Brake pedal solid when depressed with no brakes available. I will request the bad module from the dealer. No brakes is an extremely dangerous condition. The motorcycle is in a Harley Davidson getting the module replaced. This catastrophic failure happened with no warnings or symptoms.

NHTSA ID

11665136

Incident

Apr 12, 2025

The guard/spring housing locater on the rotor behind the drive sprocket developed a fatigue crack, it propagated approximately half way around the circumference before separating and then being pulled thru between the drive chain and sprocket . this caused the drive train to seize up locking up the engine and rear wheel and damaging the engine. being a motorcycle this can lead to a serious injury or death crash. fortunately for me it let go at low speed.

NHTSA ID

11471559

Incident

Jun 24, 2022

When approaching an intersection I went to apply brakes and could not because lever was frozen this resulted in my bike to coast into the intersection I was fortunate the vehicle coming was able to stop.I was told my abs system had failed and would need replaced! The issue was blamed on fluid and lack of flushing and replacement it.The fluid was replaced by dealer 5 months earlier so I’m not buying the fluid is the culprit.Bike has 12,000 miles on it.

NHTSA ID

11441177

Incident

Nov 21, 2021

TL* THE CONTACT OWNS A 2009 HARLEY-DAVIDSON FLHTCU. WHILE OPERATING THE VEHICLE, THE FRONT BRAKES MALFUNCTIONED AND THE FRONT BRAKE LEVER COULD NOT BE PRESSED TO STOP THE MOTORCYCLE. THE MOTORCYCLE WAS TAKEN TO HARLEY-DAVIDSON EASTGATE (699 CINCINNATI POTAVIA PIKE, CINCINNATI, OH) WHERE IT WAS DIAGNOSED THAT THE VALVE IN THE ABS MODULE MALFUNCTIONED AND THE MODULE NEEDED TO BE REPLACED. THE FAILURE WAS REPAIRED. THE CONTACT RECEIVED A RECALL NOTICE FOR NHTSA CAMPAIGN NUMBER: 18V076000(SERVICE BRAKES) IN JULY OF 2018, BUT THE PARTS FOR THE REPAIR WERE NOT AVAILABLE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND DID NOT ASSIST. THE FAILURE MILEAGE WAS 43,176.

NHTSA ID

11155634

Incident

Nov 1, 2018

Mileage

43,176 mi

TL* THE CONTACT OWNS A 2009 HARLEY-DAVIDSON FLHTCU. THE CONTACT STATED THAT THE FRONT BRAKES FAILED TO FULLY ENGAGE AND FUNCTION PROPERLY. THE CONTACT STATED THAT THE VEHICLE WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 18V076000 (SERVICE BRAKES, HYDRAULIC). THE CONTACT SCHEDULED AN APPOINTMENT WITH WAR HORSE HARLEY-DAVIDSON (5331 N US HWY 441, OCALA, FL 34475, 1-(352) 732-2488) AND WAS PROVIDED WITH A REMEDY FOR THE RECALL REPAIR FROM THE MANUFACTURER; HOWEVER, THE FAILURE RECURRED. THE DEALER REFUSED TO TEST DRIVE THE VEHICLE, INDICATING THAT IT WAS NOT SAFE. THE MANUFACTURER WAS CONTACTED. THE VEHICLE REMAINED PARKED AT THE CONTACT'S RESIDENCE. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

11130210

Incident

Apr 2, 2018

ABS HCU SUDDENLY FAILED CAUSING FRONT BRAKE LEVER TO BECOME SO HARD IT IS ALMOST UNSQUEEZABLE. LUCKILY THIS HAPPENED WHILE STATIONARY IN MY GARAGE ON INITIAL IGNITION ON CYCLE. I UNDERSTAND THINGS FAIL BUT FOR ABS TO FAIL IN A WAY TO LOOSE ALL BRAKING WITHOUT WARNING IS REDICULOUS. HOW COULD NHTSA LET HARLEY DAVIDSON BLAME THIS ON FLUID OR CONSUMER? ARE YOU IMPLYING THAT HARLEY TOURING OWNERS OF 2008-11 ARE THE ONLY ONES WHO DIDNT FLUSH BRAKE FLUID? MY FLUID WAS ALWAYS FLUSHED. ITS A DEFECTIVE MODULE. COME ON NHTSA WAKE UP!

NHTSA ID

11091997

Incident

Apr 30, 2018

Mileage

35,000 mi

REAR BRAKES FAILED TO OPERATE. THE REAR BRAKE PEDAL WOULD NOT MOVE WHEN PRESSURE IS APPLIED WITH FOOT. THE HARLEY RECALL ONLY CHANGES THE BRAKE FLUID WHICH IS NOT THE CAUSE OF THE PROBLEM. THE ROOT CAUSE OF THE MALFUNCTION IS THE ABS MODULE IS A DEFECTIVE DESIGN. HARLEY CLAIMS A LACK OF FLUID CHANGE IS THE CAUSE. THIS A COVER UP BY HARLEY TO KEEP FROM HAVING TO REPLACE ALL OF THE ABS MODULES ON THEIR DANGEROUS MOTORCYCLES ON THE ROAD. THIS IS THE ONLY VEHICLE THAT I HAVE EVER HEARD OF THAT MUST HAVE THE BRAKE FLUID CHANGED EVERY TWO YEARS ( JUST A COVER UP BY HARLEY) THIS IS A SERIOUS DEFECT THAT IS VERY DANGEROUS AND COULD COST LIVES ON THE ROAD.

NHTSA ID

11089758

Incident

Mar 3, 2018

Mileage

12,800 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.