2009 Harley-Davidson Flhtcuse4

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.

THIS OCCURRED WHEN THE MOTORCYCLE WAS IN A TRANSPORT CARRIER. THE BIKE WAS SECURED INSIDE THE TRANSPORT TRAILER WITH THE KEY SO THE ALARM SHOULD NOT ACTIVATE THE LED LOAD BALANCER FROM KURYAKYN CAUGHT ON FIRE, THIS IS AN AFTERMARKET PART CERTIFIED BY HARLEY DAVIDSON FOR THIS APPLICATION. WHEN I CONTACTED KURYAKYN ABOUT IT, THEY SAID THEY KNEW ABOUT THE PROBLEM BUT NEVER RECALLED THE PARTS AND TOLD ME THE REPLACEMENT PART TO ORDER. THEY TOLD ME IT'S BECAUSE THE ALARM WAS ACTIVE ON THE BIKE AND CAUSED THE LOAD BALANCER TO OVERHEAT AND CATCH FIRE.

NHTSA ID

11154537

Incident

Sep 28, 2018

Mileage

48,732 mi

INNER PRIMARY STARTED MAKING NOISE AND RUNNING ROUGH.

NHTSA ID

11118204

Incident

Aug 4, 2018

Mileage

28,000 mi

FRONT BRAKE LEVER FROZEN, WILL NOT MOVE, ABS LIGHT ON, NO FRONT BRAKES. MOTORCYCLE WAS STATIONARY.

NHTSA ID

10933783

Incident

Dec 7, 2016

Mileage

11,780 mi

I DECIDED ONE MORNING TO RIDE MY BIKE DOWN TO THE BMV TO RENEW LICENSE PLATES. THE RIDE DOWN TO THE BMV BOTH FRONT AND REAR BRAKES FUNCTION AND OPERATE PROPERLY. WHEN I GET BACK ON THE BIKE TO LEAVE, I GET READY TO STOP JUST PRIOR TO ENTERING THE HIGHWAY AND MY REAR BRAKE PEDAL IS ROCK SOLID WITH NO TRAVEL AND NO REAR BRAKES WHATSOEVER. I DID HAVE FRONT BREAKS, BUT BEING SURPRISED BY NOT HAVING ANY REAR BRAKES I OVERCOMPENSATED MY FRONT BRAKES ALMOST SPILLING THE BIKE INTO TRAFFIC. AFTER READING MANY HARLEY DAVIDSON FORUMS WITH FOLKS WHO HAVE HAD THIS SAME ISSUE AND HAVING DONE SOME MECHANICAL TESTING MYSELF ALTHOUGH I AM NOT A CERTIFIED MECHANIC I AM CONVINCED THAT THE ABS SYSTEM MALFUNCTIONED, LEAVING BRAKING DANGEROUS. THE ABS UNIT IS DESIGNED TO DEFAULT TO NORMAL HYDRAULIC BRAKING IF IT MALFUNCTIONS, IT DID NOT DEFAULT IT JUST BECAME IN OPERABLE! THIS IS A VERY DEADLY CONCERN TO ME. I WAS SURPRISED NOT TO SEE COMPLAINTS OR ACTION OF THIS ANYWHERE ON YOUR SITE AS I READ MANY FORUMS COMPLAINING ABOUT THIS ISSUE.FYI, I AM 56 YEARS OLD AND HAVE BEEN RIDING A MOTORCYCLE SINCE I GOT MY LICENSE AT 16 YEARS OLD. I LOG THOUSANDS OF MILES ANNUALLY AS A MOTORCYCLIST. I DO NOT FEEL SAFE ON THIS MOTORCYCLE ESPECIALLY WITH MY WIFE ON THERE. I WILL NOT RIDE THIS MOTORCYCLE AGAIN TILL I CONVERT THE ABS TO A FULL TRADITIONAL HYDRAULIC SYSTEM. CAN YOU CONFIRM FOR ME WHETHER THERE HAVE BEEN SIMILAR COMPLAINTS BECAUSE MAYBE I JUST HAVE NOT BEEN IN THE RIGHT SECTION TO SEE THEM. THANK YOU.

NHTSA ID

10874995

Incident

May 11, 2016

Mileage

15 mi

THE REAR WHEEL BEARING FAILED SEVERELY DAMAGING THE REAR WHEEL AND BRAKE. THE MOTORCYCLE STARTED SHAKING AND WOBBLING. IT WAS DIFFICULT TO BRING IT TO A STOP AND STAY UPRIGHT.

NHTSA ID

10462651

Incident

Apr 13, 2012

Mileage

21,800 mi

TL* THE CONTACT OWNS A 2009 HARLEY DAVIDSON MOTORCYCLE, FLHTCUSE4 EQUIPPED, WITH DUNLOP D407 P180/65/16 TIRES. THE CONTACT STATED THAT HE HAD EXPERIENCED A RECURRING FAILURE INVOLVING AN ABNORMAL AND EXCESSIVE VIBRATION WHILE DRIVING AT VARIOUS SPEEDS. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT WAS INFORMED THE TIRES WERE DEFECTIVE. THE FRONT TIRE WAS REPLACED AND THE FAILURE PERSISTED. THE CONTACT EVENTUALLY REPLACED BOTH TIRES. THE FAILURE MILEAGE WAS 5,200 AND THE CURRENT MILEAGE WAS 8,769.

NHTSA ID

10331547

Incident

May 21, 2009

Mileage

5,200 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.