2009 Harley-Davidson Flhtcutg

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 REAR BRAKES ON A 2009 HD TRIKE HAS VERY LITTLE STOPPING POWER,HARLEY KNOWS IT HAS A PROBLEM BECAUSE THEY STARTED PUTTING BIGGER BRAKES ON THE 2011 MODELS. I THOUGHT THAT THEY WOULD HAVE TO FIX THE 2009,AND 2010 MODELS.BUT THERE NEVER WAS A RECALL ON THEM.THERE IS A SAFETY PROBLEM WHEN YOU CAN'T STOP. PLUS NOW MY REAR BRAKES QUIT WORKING ALL TOGETHER.

NHTSA ID

11071954

Incident

Oct 30, 2017

Mileage

25 mi

TL* THE CONTACT OWNS A 2009 HARLEY DAVIDSON FLHTCUTG. THE CONTACT STATED WHILE DRIVING VARIOUS SPEED THERE WAS A SLIGHT VIBRATION WHICH CAUSED TWO BOLTS TO DETACH FROM THE EXHAUST. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER WHO STATED THAT THE ENGINE MOUNT DISLODGED AND THE HEAD WOULD NEED TO BE REPLACED FOR THE SECOND TIME. THE VEHICLE WOULD BE REPAIRED UNDER THE SERVICE WARRANTY ONCE THE PART BECAME AVAILABLE. THE MANUFACTURER WAS NOT NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 10,219.

NHTSA ID

10536020

Incident

Dec 12, 2012

Mileage

10,219 mi

ON THE ABOVE DATE THIS VEHICLE CAUGHT ON FIRE LESS THAN A MINUTE AFTER STARTING IT. I HAD RODE THIS VEHICLE TO WORK AND WAS AT WORK FOR AROUND TWO HOURS. UPON LEAVING WORK, I STARTED THE MOTORCYCLE WITHOUT GETTING ON AND WAS REACHING TO PUT ITEMS IN THE TRUNK WHEN THE FIRE STARTED. WHEN WALKING UP TO THE VEHICLE I DID NOT SMELL GASOLINE OR NOTICE ANY LEAKING FUEL BEFORE STARTING THE MOTORCYCLE. THE MOTORCYCLE WAS ENGULFED IN FLAMES VERY QUICKLY. I WAS VERY CLOSE TO BEING BURNED. SOME CO-WORKERS AND MYSELF ATTEMPTED TO PUT OUT THE FIRE, BUT WERE UNABLE TO GET CLOSE ENOUGH DUE TO THE INTENSE HEAT AND FLAMES. THE FIRE DEPARTMENT ARRIVED FAIRLY QUICKLY TO PUT THE FIRE OUT, BUT THE VEHICLE WAS A TOTAL LOSS. THE FIRE MARSHAL STATED THAT IT WAS PROBABLY DUE TO MECHANICAL FAILURE. TO THIS DATE HARLEY-DAVIDSON HAS NOT RESPONDED TO MY INQUIRIES ABOUT THIS INCIDENT AND HAS REFUSED TO TAKE ANY RESPONSIBILITY FOR THIS FIRE. *TR

NHTSA ID

10433622

Incident

Sep 4, 2010

Mileage

1,500 mi

RIDER EXPERIENCED 2ND DEGREE BURNS DUE TO HEAT EMANATING FROM THE ENGINE DURING HOT WEATHER AND STOP-AND-GO TRAFFIC; REAR CYLINDER SHUTS OFF AND THEN MOTORCYCLE RUNS POORLY (NO ACCELERATION); ALSO AFFECTS BRAKING (REAR BRAKE GETS "MUSHY"); HAS RESULTED IN DISCOLORATION OF HORN AND AIR FILER COVER; OIL PRESSURE DROPS TO 0; HAVE HAD TO REPLACE 2 QTS. OF OIL IN 1300 MILES; LITERALLY WAS "SMOKING"; AMBIENT TEMP. PEGGED OUT AT 120 DEGREES. EXTREME SAFETY HAZARD TO RIDER AND DEALER CAN OFFER NO SOLUTION; CAN'T EVEN TUNE THE MOTORCYCLE BECAUSE THEY CAN'T DYNO A TRIKE. *TR

NHTSA ID

10410669

Incident

May 20, 2011

Mileage

4,000 mi

HEAT COMING OFF THE EXHAUST/ENGINE MAKES THE BIKE UNBEARABLE TO RIDE...ESPECIALLY WHEN THE WEATHER GETS WARMER AND YOU ARE STOPPED OR GOING SLOWLY IN TRAFFIC. IT WILL BURN YOUR RIGHT CALF SEVERELY AND HARLEY DAVISDON REFUSES TO ADMIT THE PROBLEM OR OFFER A REMEDY FOR IT. ALSO REAR BRAKES SQUEAL CONSTANTLY AND ARE BARELY ADEQUATE FOR STOPPING. *TR

NHTSA ID

10400948

Incident

May 14, 2011

Mileage

10 mi

SERVICE BULLETIN M1508 (REV D): 2009-2025 TRIKE PLATFORM - REVERSE MOTOR. PURPOSE: Revision C. To inform dealers of a running change for the new reverse motor (Part No. 83388-09C) for Trike models. As of January 28, 2020 all Trike platform vehicles will be manufactured using the new reverse motor. The new reverse motor will be used to replace reverse motor assemblies (Part No. 83388-09, 83388-09A,83388-09B) that have failed diagnostics. Refer to Table 3. This motor contains several improvements for better motor durability. A new procedure has been added, Refer to PINION EXTENDS BUT REVERSE MOTOR STALLS OR SPINS SLOWLY. REV D: Updated: Guide. Add link to: PINION EXTENDS BUT REVERSE MOTOR STALLS OR SPINS SLOWLY

GENUINE MOTOR PARTS AND ACCESSORIES BULLETIN PAB1182: TRIKE SADDLEBAGS KIT INFORMATIONAL UPDATE. PURPOSE: Initial release. This bulletin informs dealers that the Trike Saddlebags kit (Part No. 84031-11) has an informational update: The drill template that is inside the kit, is only used for 2009-2025 Trike models. The electronic version of this instruction sheet which is located in Service Information Portal (SIP), will have the drill template as an attachment for 2026 and later Trike models (see service bulletin M1714). It will not be included inside the kit or directly attached to the instruction sheet.

SERVICE BULLETIN M1508 (REV C): 2009-2025 TRIKE PLATFORM - REVERSE MOTOR. PURPOSE: Revision C. To inform dealers of a running change for the new reverse motor (Part No. 83388-09C) for Trike models. As of January 28, 2020 all Trike platform vehicles will be manufactured using the new reverse motor. The new reverse motor will be used to replace reverse motor assemblies (Part No. 83388-09, 83388-09A,83388-09B) that have failed diagnostics. Refer to Table 3. This motor contains several improvements for better motor durability. A new procedure has been added, Refer to PINION EXTENDS BUT REVERSE MOTOR STALLS OR SPINS SLOWLY. REV C: Update Removal and Assembly (R&I) of the Solenoid. Updated: DISASSEMBLE, ASSEMBLE and Install Electrical Kit.

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 M1689: 2009-2010 TRIKE TRANSMISSION HOUSING IS OBSOLETE. PURPOSE: Initial release. This bulletin informs dealers that Transmission Case (Part No. 83978-09) for 2009-2010 Trikes, is obsolete. Required Dealer Action: 1. If Transmission Case (Part No. 83978-09) is no longer available to order for a 2009-2010 Trike, order replacement Transmission Case (Part No. 83978-11). 2. Remove the 30 tooth drive sprocket and install either a new 32 tooth sprocket (Part No. 35000152A) or reuse the original 32 tooth sprocket, if it's in good condition.

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).