Common HD problems

[Momz]

Common Problems With Harley-Davidson Motorcycles (Part 1) Featured
Written by Clive Cassidy     July 06, 2012     

The 2003 Harley-Davidson FLHRCI Road King Classic was among the many motorcycles recalled by Harley-Davidson in 2003.


Despite Harley-Davidson’s iron-clad image in American culture, numerous flaws have been exposed over the years. Recalls have been somewhat regular, including some with hundreds of thousands of bikes needing repairs. Below, we’ll examine a few major problems that have occurred over the past decade with Harley-Davidson motorcycles.

Tail Light
Multiple 2003 Harley models suffered from a defect in the tail light. Although it seemed minor, the tail light bulb was susceptible to falling out of it’s socket, rendering the tail light and brake light inoperative. This posed a risk of a crash, given that a driver wouldn’t have a clear indication that the biker was slowing down and a lack of lighting at night.

Harley recalled nearly 36,000 bikes in mid-2004. These included the following models:

FLHPI 2003
FLHPEI 2003
FLHR 2003
FLHRCI 2003
FLHT 2003
FLHTC 2003
FLHTCI 2003
FLHTI 2003
FLHTPI 2003
FLTR 2003
FLTRI 2003
FXD 2003
FXDI 2003
FXDL 2003
FLHT 2003
FXDP 2003
FXDWG 2003
FXDWGI 2003
FXDX 2003
FXDXI 2003
FXDXT 2003
XL1200 2003
XL1200C 2003
XL1200R 2003
XL1200S 2003
XL883 2003
XL883C 2003
XL883R 2003
XL883 HUGGER 2003
To correct this problem, Harley simply replaced the bulbs.

Fuel Tank
In 2009, the National Highway Traffic Safety Administration reported that the front-end mounts on Harley touring bikes could distort in a front-end crash. Such a crash could have resulted in a fuel leak, which could then ignite and injure or kill the rider.

As a result, Harley-Davidson recalled nearly 112,000 motorcycles in December of 2009. These included the following models:

FLHP 2009-2010
FLHPE 2009-2010
FLHR 2009-2010
FLHR SHRINE 2009-2010
FLHRC 2009-2010
FLHT 2009-2010
FLHTC 2009-2010
FLHTCU 2009-2010
FLHTCU SHRINE 2009-2010
FLHTCU W/SC 2009-2010
FLHTCU4-CVO 2009
FLHTCUSE4 2009
FLHTCUSE5 2010
FLHTCUTG 2010
FLHTK 2010
FLHTP 2009-2010
FLHX 2009-2011
FLHXXX 2010
FLTR 2009
FLTR3-CVO 2009
FLTRSE3 2009
To correct this problem, Harley-Davidson installed a left and right brace on the mentioned models. The upgrade was free of charge.

Brake Light and Fluid
Two issues with the braking system occurred on numerous 2009 to 2012 models. First, the rear brake light switch was exposed to excessive exhaust heat, which could cause it to activate the brake light without the brakes being applied or fail to do so altogether. Second, the exposure to excessive heat could have lead to a leak of brake fluid, thereby increasing the risk of a crash.

As a result, Harley recalled approximately 300,000 motorcycles in October of 2011, nearly 251,000 of which were in the United States. These included the following models:

FLHP 2009-2012
FLHPE 2009-2011
FLHR 2009-2012
FLHRC 2009-2012
FLHT 2009-2010
FLHTC 2009-2012
FLHTCU 2009-2012
FLHTCUSE4 2009
FLHTCUSE5 2010
FLHTCUSE6 2011
FLHTCUSE7 2012
FLHTCUTG 2009-2012
FLHTK 2010-2012
FLHTP 2009-2012
FLHX 2009-2012
FLHXSE 2010
FLHXSE2 2011
FLHXSE3 2012
FLHXXX 2011
FLTR 2009
FLTRSE3 2009
FLTRU 2010-2012
FLTRUSE 2011
FLTRX 2010-2012
FLTRXSE 2012
To correct this problem, Harley installed a kit for the rear brake light. This was done free of charge.

Conclusion
Despite numerous recalls and safety issues, Harley-Davidson’s iconic status lives on in the modern world. Performance and safety issues with Harley bikes have been well-publicized and have helped fuel a debate as to the quality of the brand.

Some can’t get enough of the Harley brand while others believe it represents image, not quality. Just ask a few bikers or search a few biker forums to get an idea of the varied opinions on the quality of Harley bikes. In any event, be sure to keep safety issues in mind if you own one of the mentioned models and, of course, ride safely!

[steve 3054]

While it appears that you don't care for the brand H.D. and I was not aware of the vast amount of recalls...I believe it is the luck of the draw...on my 02 F-250 diesel I have only replaced a tail light bulb due to being defective.  I special ordered a Camaro  and the rear end gave up 75 miles later, a total lemon.  I bought a Toyota truck, don't remember the year and it was perfect.  Bought a Honda Rune and it has had 4 throttle bodies.  Bought a used Valkyrie and spent crazy money getting the rear end in shape.  Bought a H.D. Ultra 03. 55K miles later and replaced the voltage regulator and nothing else...Everything can go bad or have issues, even some people...

[rider]

When it comes to mechanical yeah some days you get chicken some days feathers and luck to me is (living under correct knowledge) but the design of the twincam camchest makes a guy wonder wth.so much for  fixn a scoot with bubblegum and bailing wire.my thing is to eachthere own.the bike dont make the man the man makes the bike.ride free fellow bikers

[wiggydotcom]

While I'm not a HD fan per se, didn't Honda have to recall a massive amount of Gold Wings about 7 yrs ago because of cracks in the frames? Just going by memory on when the recall was....but all brands are susceptible.

[alph]

wow, what it tells me is that harley's made a lot of bikes!!!  300,000 recalled because of a break light?  that's a lot of bikes!!  didn't honda only make 46,000 valkyries in 5 years? go figure.....

[cookiedough]

It wouldn't matter to the majority of HD riders whether they had 100 recalls or just one.  A lot of them, not all, ONLY believe in HD and doesn't matter about reliability, only image.

Personally, I think HD makes a decent bike and the fit and finish is usually top notch even more so than some of the Valk components like the fairing and electrical parts like cruise control, radio, speakers, etc., just don't think the price is justified to own one.

[MCRIDER]

http://www.autoblog.com/2012/03/07/toyota-recalling-camry-venza-and-tacoma/

http://www.autoblog.com/2012/04/16/toyota-announces-service-campaign-to-fix-prius-v-exhaust-problem/

http://www.autoblog.com/2012/05/21/toyota-recalling-2013-lexus-gs-350-f-sport-over-faulty-ecu/

http://www.abc.net.au/news/2010-03-02/toyota-plays-down-oil-leak-problems/347486

http://www.autoblog.com/2012/06/29/lexus-adding-over-150-000-rx-crossovers-to-pedal-entrapment-reca/

http://www.autoblog.com/2012/08/01/toyota-recalling-778-000-rav4-hs-250h-units-for-loose-suspensio/

http://www.autoblog.com/2011/11/09/toyota-recalling-550-000-vehicles-worldwide-for-potential-steeri/

http://www.autoblog.com/2011/12/06/toyota-recalling-200k-siennas-over-misprint/

http://www.autoblog.com/2011/12/29/toyota-tops-recall-list-again-in-2011-overall-number-of-u-s-re/

http://www.detroitnews.com/article/20111207/AUTO01/112070438

http://www.chicagotribune.com/classified/automotive/recalls/sns-recall-alert-2011-toyota-rav4-20120203,0,6184011.story

http://www.detroitnews.com/article/20110305/AUTO01/103050382/1148/auto01/Toyota-recalls-vehicles-over-tire-pressure-monitors

http://www.detroitnews.com/article/20110421/AUTO01/104210457/1148/auto01/Toyota-recalls-RAV4s-over-airbag-sensor-issue

http://www.detroitnews.com/article/20110426/AUTO01/104260406/1148/AUTO01/Toyota-recalling-51-000--11-Tundras

http://www.autoblog.com/2011/05/17/toyota-recalls-2007-11-tundra-for-faulty-tire-pressure-monitors/

http://m.detnews.com/autos/article?a=2011106010376&f=1213


There are many, many more for your reading pleasure. 

[sandy]

While I'm not a HD fan per se, didn't Honda have to recall a massive amount of Gold Wings about 7 yrs ago because of cracks in the frames? Just going by memory on when the recall was....but all brands are susceptible.

The cracked frames were due to a welder having lowered the heat range on his welder. It made it easier for him to do his job but penetration suffered. Six bikes actually had cracks and were replaced entirely. The heat range date and time were documented so all the suspect VIN numbers were known. All of those bikes were repaired with gussets added at the cool weld to beef up the frames.

[shortleg]

  I rode my Street Glide to this years Inzane.
I wanted to put some miles on it. It was a grate ride,
but I have to admit it was a hot one.
   I have been on 3 long ride with this bike, long being
2000 to 5000 miles I have had no problems.
  So I will say it is the luck of the draw with bikes.
My Valk has been as good to me on all my rides.
  As we all know it takes looking after your ride to get
a good ride.
          Shortleg[Dave]

[Jess Tolbirt]

  I rode my Street Glide to this years Inzane.
I wanted to put some miles on it. It was a grate ride,
but I have to admit it was a hot one.
   I have been on 3 long ride with this bike, long being
2000 to 5000 miles I have had no problems.
  So I will say it is the luck of the draw with bikes.
My Valk has been as good to me on all my rides.
  As we all know it takes looking after your ride to get
a good ride.
          Shortleg[Dave]

take the catalytic converter out of your pipes and it will ride MUCH cooler!!!

[Dogg]

But it will screw up the mapping. If ur gonna modify it in any way, check with warranty first, then if you can, do the mods. There are other, easier, cheaper ways around cooling the bike off other than removing the cats. And more effective too!

[czuch]

The newest Harley I had was a 67, Sportster. It was a very reliable and fun bike.
The other one was a Pan Head. If you went on a 100 mile ride, you needed a friend on a Honda and $100 to go get what you needed but didnt have. It too, was a great bike.
Most problems I've had with motorcycles have been between the grips and the seat.

[RainMaker]

The newest Harley I had was a 67, Sportster. It was a very reliable and fun bike.
The other one was a Pan Head. If you went on a 100 mile ride, you needed a friend on a Honda and $100 to go get what you needed but didnt have. It too, was a great bike.
Most problems I've had with motorcycles have been between the grips and the seat.

Agreed.  Most problems are with the nut that connects the seat to the handlebars.  Not brand specific.

[BigAl]

While I'm not a HD fan per se, didn't Honda have to recall a massive amount of Gold Wings about 7 yrs ago because of cracks in the frames? Just going by memory on when the recall was....but all brands are susceptible.

IT was a frame upgrade. But you have to ask yourself, would you want a faulty tail light bulb that is easily fixed or a damn frame

issue to worry you day and night wondering, is it really fixed or not.

I'll take the bulb anytime.

As far as the gas tank issue, A front end collision that hard is gonna have you sailing into the stratosphere, far way from the crash.

As far as my Harley's not a bolt astray, not a recall to date.

Maybe I'll buy a Toyota and let it run away with me and sue Toyota. A multi billion dollar Recall. Japs do it right.

NHTSA fined them billions for making the recall too late.

Many deaths and injuries, one guy even went to jail for hitting a car load of people after his Camry carrened out of control under acceleration

that was not of the drivers making. Yep the Japs do it better and hide it much better.

[wiggydotcom]

While I'm not a HD fan per se, didn't Honda have to recall a massive amount of Gold Wings about 7 yrs ago because of cracks in the frames? Just going by memory on when the recall was....but all brands are susceptible.

The cracked frames were due to a welder having lowered the heat range on his welder. It made it easier for him to do his job but penetration suffered. Six bikes actually had cracks and were replaced entirely. The heat range date and time were documented so all the suspect VIN numbers were known. All of those bikes were repaired with gussets added at the cool weld to beef up the frames.

It seems there is more to it than that. The years in question for cracked frames were the 01 to 04 Goldwings. That would hardly be from one person running a low current on his welder. Check out this link from the Goldwing Board-starting with the post from Roadie.

www.goldwingowners.com/forums/showthread.php?t=110

[MarkT]

While I'm not a HD fan per se, didn't Honda have to recall a massive amount of Gold Wings about 7 yrs ago because of cracks in the frames? Just going by memory on when the recall was....but all brands are susceptible.

The cracked frames were due to a welder having lowered the heat range on his welder. It made it easier for him to do his job but penetration suffered. Six bikes actually had cracks and were replaced entirely. The heat range date and time were documented so all the suspect VIN numbers were known. All of those bikes were repaired with gussets added at the cool weld to beef up the frames.

I didn't know that about the penetration.  However, the fix was to have a local certified welder TIG weld, adding additional weld fill in the suspect area.  Mine was done and I have pictures I took myself during the process.

[shortleg]

  My 07 Street Glide has no Catalytic converters.
When I said it was hot the temp was 103 outside.
  My Valk gets hot also.
  All bikees need stuff, Harleys just need to be
remapped and that can be done real easy.
  Blame the EPA.
  The Cats came in 09 I think.
      Shortleg[Dave]

[Momz]

I didn't mean to start a firestorm here. There has never been a perfect motorcycle built (Valks are in that group).

The article was sent to me by a friend that owns a HD custom and service facility (Fiz's Custom Cycles, Westland, MI).

But that is an awful lot of bikes to recall. 

[3fan4life]

I got out ran by a Harley today........................












I wasn't on the VALK,






I was in my Geo Prism.......................




But it was still kind of embarrassing.   

[OKIERYDER]

I bought a beautiful blue 2006 HARLEY 1200C SPORTSTER WITH 10,000 MILES 2 YEARS AGO, THE BIKE RAN PERFECT TILL LAST SUMMER 1O8*  TURN MOTOR OFF IT WOULD DIESEL ONLY WAY TO GET IT TO TURN OFF WAS PUT IN GEAR HOLD BRAKE.  TRY TO START MOTOR WOULD NOT TURN OVER TILL COOLED.  Harleys not so good in heat, Sold it.

      Sorry for the caps, must have hit after blue.

[R J]

Caps mean you are screaming............

[BigAl]

I bought a beautiful blue 2006 HARLEY 1200C SPORTSTER WITH 10,000 MILES 2 YEARS AGO, THE BIKE RAN PERFECT TILL LAST SUMMER 1O8*  TURN MOTOR OFF IT WOULD DIESEL ONLY WAY TO GET IT TO TURN OFF WAS PUT IN GEAR HOLD BRAKE.  TRY TO START MOTOR WOULD NOT TURN OVER TILL COOLED.  Harleys not so good in heat, Sold it.

      Sorry for the caps, must have hit after blue.

Rode my Beautiful Blue Electra Glide, in a 105 degree heat wave.  Ran Great.

It has been remapped. Runs richer.

Sounds like you had a carbuerated Sportster. Lean is the way they come from the Factory just like all bikes.

Heat is what it causes and that will make it diesel everytime.

Jet it but you don't have it now. That would have fixed the prob.  Sportster gets about 50 miles to the gallon. I liked the one I had.

[sidecarrick]

I got out ran by a Harley today........................

 





I wasn't on the VALK,






I was in my Geo Prism.......................




But it was still kind of embarrassing.   

   

[BigAl]

This is encouraging.

Here is a picture of a 03 lower crossmember welds that were rewelded. The safety recall successfully fixed the lower crossmember weld issue and this frame issue is history.....unfortunately all the 01 to 04 models are still affected by cracks in the frame tubing in the rear triangle of the frame.

[OKIERYDER]

I bought a beautiful blue 2006 HARLEY 1200C SPORTSTER WITH 10,000 MILES 2 YEARS AGO, THE BIKE RAN PERFECT TILL LAST SUMMER 1O8*  TURN MOTOR OFF IT WOULD DIESEL ONLY WAY TO GET IT TO TURN OFF WAS PUT IN GEAR HOLD BRAKE.  TRY TO START MOTOR WOULD NOT TURN OVER TILL COOLED.  Harleys not so good in heat, Sold it.

      Sorry for the caps, must have hit after blue.

Rode my Beautiful Blue Electra Glide, in a 105 degree heat wave.  Ran Great.

It has been remapped. Runs richer.

Sounds like you had a carbuerated Sportster. Lean is the way they come from the Factory just like all bikes.

Heat is what it causes and that will make it diesel everytime.

Jet it but you don't have it now. That would have fixed the prob.  Sportster gets about 50 miles to the gallon. I liked the one I had.

Yip, you are right on it was carbuerated. It did get the mileage you said.
Took it to Harley dealer twice and never fixed it.  It had screaming eagle pipes, jetted and stage 2 breather.

[BigAl]

01 to 04's on the Goldwing,

More rear frame section cracks Honda will never fix.

[fudgie]

Following 3 HD thru Kansas yesterday. I thought it was foil blowing off the road but it ended up being the heel part of his heel/toe shifter. He stopped and I told him he lost it 1/2 mile back. He said he barrowed one from another guy cause he lost his other one yesterday! 

[Jess Tolbirt]

But it will screw up the mapping. If ur gonna modify it in any way, check with warranty first, then if you can, do the mods. There are other, easier, cheaper ways around cooling the bike off other than removing the cats. And more effective too!

no it wont screw up the mapping, and i added xieds to mine to richen it up..removing the cats is no different than changing the headers...

[DIGGER]

I got out ran by a Harley today........................












I wasn't on the VALK,






I was in my Geo Prism.......................




But it was still kind of embarrassing.   

Race with a Harley

I raced a Harley today and after some really hard riding I managed
to PASS the guy. I was riding on one of those really, really
twisting sections of mountain road with no straight sections to
speak of and where most of the bends have warning signs that
say "MAX SPEED 20 MPH".

I knew if I was going to pass one of those monsters with those
big-cubic-inch motors, it would have to be a place like this where
handling and rider skill are more important than horsepower alone.

I saw the guy up ahead as I exited one of the turns and knew I could
catch him, but it wouldn't be easy. I concentrated on my braking and
cornering. Three corners later, I was on his mudguard. Catching him
was one thing; passing him would prove to be another.

Two corners later, I pulled up next to him as we sailed down the
mountain. I think he was shocked to see me next to him, as I nearly
got by him before he could recover. Next corner, same thing. I'd
manage to pull up next to him as we started to enter the corners but
when we came out he'd get on the throttle and out-power me. His
horsepower was almost too much to overcome, but this only made me
more determined than ever.

My only hope was to out-brake him. I held off squeezing the lever
until the last instant. I kept my nerve while he lost his. In an
instant I was by him. Corner after corner, I could hear the roar of
his engine as he struggled to keep up. Three more miles to go before
the road straightens out and he would pass me for good.

But now I was in the lead and he would no longer hold me back. I
stretched out my lead and by the time we reached the bottom of the
canyon, he was more than a full corner behind. I could no longer see
him in my rear-view mirror.

Once the road did straighten out, it seemed like it took miles
before he passed me, but it was probably just a few hundred yards. I
was no match for that kind of horsepower, but it was done. In the
tightest section of road, where bravery and skill count for more
than horsepower and deep pockets, I had passed him. Though it was
not easy, I had won the race to the bottom of the mountain and I had
preserved the proud tradition of one of the best bits of Brit iron.

I will always remember that moment. I don't think I've ever pedaled
so hard in my life. And, some of the credit must go to Raleigh
cycles, as well. They really make a great bicycle...