2004 Harley-Davidson FLHR: complaints, problems and recalls

SUDDEN AND COMPLETE LOSS OF REAR BRAKE; PEDAL GOES TO THE MAXIMUM LIMIT WITHOUT RESISTANCE. *TR

Look up ODI 10627377 at NHTSA ↗

TL* THE CONTACT OWNS A 2009 HARLEY DAVIDSON FLHR. THE CONTACT STATED THAT THE FRONT BRAKE FAILED TO ENGAGE WHILE ATTEMPTING TO COME TO A COMPLETE STOP. AS A RESULT, THE CONTACT DROVE THROUGH THE INTERSECTION. THE CONTACT INSPECTED THE MOTORCYCLE AND FOUND THAT THE ABS MODULE INTERLOCK BRAKE SYSTEM FAILED. THE CONTACT DISCONNECTED THE ABS FUSE. THE MOTORCYCLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 19,000. UPDATED 5/12/15*CN UPDATED 10/2/2017*CN

Look up ODI 10701606 at NHTSA ↗

TL* THE CONTACT OWNS A 2010 HARLEY-DAVIDSON FLHR. WHILE DEPRESSING THE REAR BRAKE PEDAL AT 40 MPH IN INCLEMENT WEATHER, THE VEHICLE FAILED TO RESPOND WITHOUT WARNING. WHEN THE FRONT BRAKE WAS ENGAGED, THE CONTACT CRASHED INTO THE PAVEMENT. THE CONTACT SUSTAINED INJURIES TO THE LEFT SHOULDER, HEAD, AND GROIN. THE CONTACT ALSO SUSTAINED ROAD RASH THAT REQUIRED MEDICAL ATTENTION. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC, BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAIL…

Look up ODI 10884205 at NHTSA ↗

WHILE TRYING TO STOP AT A STOP SIGH THE FRONT BRAKES WOULD NOT WORK AT ALL AFTER GETTING STOPPED AND PARKING THE BIKE, THE BREAK LEVER WOULD NOT MOVE. AFTER SEVERAL ATTEMPTS PULLING ON THE BREAK IT LOOSENED UP SO I RODE BIKE TO REPAIR SHOP. EVERY TIME THE FRONT BREAK WOULD ENGAGE (WHICH WAS NOT EVERY TIME), IT WOULD CATCH AND LOCK UP THE FRONT TIRE CAUSING ME TO DROP THE BIKE ONCE. REPAIR SHOP SAID THE ENTIRE ABS SYSTEM WAS NOT WORKING. HARLEY CUSTOMER SERVICE SAID I WOULD HAVE TO ALLOW THEM TO FIX IF BUT THAT IT WOULD BE AT THEIR NORMAL…

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ABS LOCK OUT OF FRONT BRAKES. LEVER SEIZED LEAVING RIDER WITHOUT FRONT BRAKES. CAME TO A STOP IN REST AREA WITH FUNCTIONAL BRAKES AND AFTER A SHORT BREAK HANDLE WAS SIZED AND FRONT BRAKE WAS NO LONGER FUNCTIONAL.

Look up ODI 11414809 at NHTSA ↗

The front brake on my bike got real hard when depressed and brake would engage. I bled the brakes but because of being ABS I could not do so. I called manufacter and they said no recall was issued. Called dealer and they said could be fixed for a price. There are 33,336 miles on bike. I understand that this a problem and a recall was issued prior to the year of my bike, it doesn't seem to have been resolved. It is winter and not using bike and waiting to see if there may be a recall

Look up ODI 11493622 at NHTSA ↗

FLY BY WIRE THROTTLE FAILED, THROTTLE ONLY WORKS IN IDLE MODE. THIRD TIME THIS HAPPENED, LAST TIME WAS A 400 HUNDRED DOLLAR TOW PLUS SEVEN HUNDRED DOLLARS IN HAULING COST. REPLACED TGS (THROTTLE GRIP SENSOR), TEMPORARILY FIXED FOR TWO MILES. THROTTLE WIRE LOOM NOT AVAILABLE FROM HARLEY, BACK ORDERED UNTIL 09/14/2010. KNOW FOR A FACT OF TWO OTHER '08 HD TOURING BIKE THIS HAPPENED ON. *TR

Look up ODI 10354318 at NHTSA ↗

PULLED UP TO A STOPLIGHT EVERYTHING WAS FINE, WENT TO PULL AWAY AFTER LIGHT CHANGED BIKE LOST POWER FELT LIKE IT WAS RUNNING ON ONE CYLINDER AND WOULD NOT ACCELERATE. MANAGED TO GET OUT OF TRAFFIC WITHOUT GETTING HIT SHUT BIKE OFF THEN RESTARTED THE BIKE AND ACCELERATION RETURNED TO NORMAL. CHECKED FOR CODES AND HAD A P2135 THROTTLE POSITION SENSOR CLEARED CODES AND HAS NOT RETURNED AS OF YET BUT GETTING READY TO TAKE A TRIP AND DON'T TRUST THIS BIKE.... *TR

Look up ODI 10523838 at NHTSA ↗

HEADLIGHTS AND PASSING LAMPS FLICKER ON AND OFF INTERMITTENTLY. MAJOR SAFETY CONCERN AT NIGHT. PROBLEM APPEARS TO BE RELATED TO WIRING FOR THE HEADLIGHT AND PASSING LAMPS. HAPPENS WHEN YOU TURN THE HANDLEBARS LEFT OR RIGHT. HAPPENS SITTING STILL AND WHILE MOTORCYCLE IS IN MOTION.

Look up ODI 11001841 at NHTSA ↗

AT AN INTERSECTION AFTER LIGHT CHANGED, ENGINE LOST ALL POWER AS I TRIED TO MAKE MY TURN. HAD TO IDLE AT ABOUT 5 MPH INTO A GAS STATION PARKING LOT WHILE TRAFFIC WENT AROUND ME. DIAGNOSIS WAS A BAD THROTTLE BODY MODULE. THIS IS MY PRIMARY MEANS OF TRANSPORTATION AND THE DEALER IS STILL TRYING TO GET THE REPLACEMENT PART FOR A WEEK NOW. FROM WHAT I'VE READ THIS IS A KNOW ISSUE WITH H-D TOURING MODELS GOING BACK TO 2008 AND MAY OCCUR AGAIN IN THE FUTURE. *TR

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CLUTCH SAFETY SWITCH FAILURE.

Look up ODI 11124101 at NHTSA ↗

STOCK COMPENSATOR FAILED AT 12300 MILES. HD SUGGESTS REPLACING WITH UPGRADED SCREAMING EAGLE COMPENSATOR. HIGH SPEED FAILURE COULD RESULT IN SERIOUS BODILY INJURY. *TR

Look up ODI 10511738 at NHTSA ↗

ECM PLUG CAUSED BIKE TO BUCK AND RUN ERRATICALLY. BROUGHT BACK TO DEALER NUMEROUS TIMES UNTIL THEY CHANGED THE PLUG. THEY BLAMED ON THE AFTERMARKET SEAT MADE BY MUSTANG SEAT FOR THE BIKE BUT IT HAPPENED WITH THE STOCK SEAT AS WELL. IT SEEMS OTHERS ARE SAYING THE SAME HAPPENED TO THEM WITH STOCK SEATS. *TR

Look up ODI 10496114 at NHTSA ↗

RIGHT SIDE OF THE ENGINE OVERHEATING TO THE POINT OF BURNING MY PANTS AND LEGS. COMPLETELY UNACCEPTABLE FOR A $20K BIKE. HARLEY STATES THAT IS IS NORMAL. THERE IS NOTHING NORMAL FOR A RIDER TO BURN HIS/HER LEGS. *TR

Look up ODI 10616320 at NHTSA ↗

ENGINE GETS HOT AND STALLS OUT IN TRAFFIC DUE TO ENGINE CASE FILLING WITH OIL, HARLEY CALLS THIS WET SUMPING, HUNDREDS OF BIKE ENGINES ARE BLOWING UP ALL OVER THE WORLD, ITS ALL OVER THE INTERNET, WITH HARLEYS NEW M8 ENGINE, THE BIKE STALLS OUT WITH NO WARNING, IVE HAD CARS AND TRUCKS ALMOST RUN ME OVER.

Look up ODI 11097743 at NHTSA ↗

TL* THE CONTACT OWNS A 2008 HARLEY DAVIDSON ROAD KING CLASSIC MOTORCYCLE. THE CONTACT STATED THAT THERE WAS A LOUD NOISE COMING FROM THE BOTTOM OF THE VEHICLE. THE CONTACT DIAGNOSED THE FAILURE AND DETERMINED THAT THE WHEEL BEARING WAS DEFECTIVE. THE DEALER REPLACED THE WHEEL BEARING NUMEROUS TIMES, BUT THE FAILURE WOULD RECUR. THE MANUFACTURER WAS NOTIFIED, BUT DENIED ANY ASSISTANCE WITH REPAIRS TO THE VEHICLE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 10,000 AND THE CURRENT MILEAGE WAS 45,000. THE VIN WAS UNAVAILABLE.

Look up ODI 10450322 at NHTSA ↗

TL* THE CONTACT OWNS A 2010 HARLEY DAVIDSON ROAD KING. THE CONTACT STATED THAT WHILE HAVING ROUTINE MAINTENANCE PERFORMED, HE WAS NOTIFIED THAT THE MOTORCYCLE WAS MAKING AN ODD NOISE. THE TECHNICIAN DIAGNOSED THAT THE PRIMARY CARRIER BARRING WAS DEFECTIVE AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 28,000. UPDATED 02/27/14*LJ

Look up ODI 10536886 at NHTSA ↗

VEHICLE IS SUBJECT TO NHTSA RECALL NO.18V734. HAVE BEEN ON DEALERS LIST FOR RECALL COMPLETION FOR APPROXIMATELY A MONTH STILL WAITING. DEALERS NAME IS [XXX] IN [XXX]. DEALER ADVISES WAIT TIME MAY BE SEVERAL MORE MONTHS. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

Look up ODI 11156690 at NHTSA ↗

SAME ISSUE WITH 2017-2017 RECALL ON HARLEY CLUTCHES PURCHASED A 2019 ROAD KING BY HARLEY AND THE CLUTCH WILL NOT RELEASE THE GEAR IN 1ST/ BIKE CREEPS FORWARD WHEN CLUTCH HANDLED IS PULLED IN. WONT GO INTO NEUTRAL WITH OUT DOUBLE CLUTCHING THE CLUTCH HANDLE.OUT OF TOWN DEALERSHIP INSPECTED AND FOUND MASTER CYLINDER COVER GASKET SUCKED DOWN AND NOT FLUID. THEY FLUSHED THE CLUTCH SYSTEM AND REFILLED. WORKED FOR TEST DRIVE BUT WHEN I HAD PUT 100 MORE MILES ON THE BIKE ISSUES CAME BACK. THIS BIKE HAD A LITTLE OVER 800 MILES ON IT.

Look up ODI 11210265 at NHTSA ↗

TL* THE CONTACT OWNS A 2019 HARLEY-DAVIDSON FLHR. THE CONTACT STATED THAT THE CLUTCH FAILED TO PROPERLY STOP THE MOTORCYCLE. THE FRONT BRAKE HAD TO BE APPLIED TO PREVENT A CRASH. ALSO, THE MOTOR STALLED THREE TIMES WHILE AT A STOP THEN IT QUIT COMPLETELY. THE DEALER (M & S HARLEY-DAVIDSON, 60 FALLING SPRING RD, CHAMBERSBURG, PA 17202, [phone removed]) REPLACED THE PART AND STATED THAT THE VEHICLE WAS EXCLUDED FROM NHTSA CAMPAIGN NUMBER: 18V734000 (POWER TRAIN); ALTHOUGH THE FAILURE WAS SIMILAR. THE MOTORCYCLE WAS REPAIRED. THE MANUFACTURER WAS …

Look up ODI 11217047 at NHTSA ↗

TL* THE CONTACT OWNS A 2008 HARLEY DAVIDSON ROAD KING FLHR MOTORCYCLE. THE CONTACT STATED THAT BEFORE STARTING THE VEHICLE, HE NOTICED FUEL LEAKING FROM THE FUEL TANK. THE VEHICLE WAS NOT REPAIRED AND THE MANUFACTURER WAS NOTIFIED. THE VIN WAS NOT AVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 6,000.

Look up ODI 10537735 at NHTSA ↗

BIKE GOES INTO LIMP MODE, IDLE ONLY, NO THROTTLE RESPONSE,WHILE DRIVING DOWN THE ROAD. THE FIRST TIME I WAS GOING 60 MPH IN TRAFFIC AND ALMOST GOT RAN OVER. IT HAS HAPPENED SEVERAL TIMES SINCE, AND A FEW AT 70 PLUS MPH. FORTUNATELY I WAS ABLE TO GET OFF THE ROAD WITHOUT A PROBLEM. BUT I WERE TO BE PASSING IN TRAFFIC OR HUNG IN THE CENTER LANE. IT COULD BE TRAGIC. THE FIRST TIME I TOOK IT TO THE DEALER , THE SERVICE MANAGER ACTED AS IF HE NEVER HEARD OF THE PROBLEM. WHEN I TOLD HIM THAT IT IS EASY TO FIND INFO ON THE INTERNET, INCLUDING A HARLEY…

Look up ODI 10520570 at NHTSA ↗

WHILE PASSING A VEHICLE AT 55 MPH MY MOTORCYCLE THROTTLE BY WIRE SYSTEM WENT INTO THE LIMP MODE (THE THROTTLE IS NO LONGER FUNCTIONING). I'M AM BESIDE THE VEHICLE I'M ATTEMPTING TO PASS AND HAD A DIFFICULT TIME TRYING TO GET BACK INTO THE DRIVING LANE. LUCKILY, I WAS ABLE TO DO SO BEFORE ONCOMING TRAFFIC. I UNDERSTAND THIS IS A COMMON OCCURRENCE SINCE 2008 WITH THE THROTTLE BY WIRE SYSTEM. IT IS A MANUFACTURERS DESIGN DEFECT AND WHY HARLEY HAS NOT RECALLED IT IS BEYOND ME. IS NHTSA AND HARLEY WAITING FOR PEOPLE TO GET KILLED BEFORE INITIATING …

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THE ENGINE WILL STALL AT A TRAFFIC LIGHT, AND ACCELERATING FROM THE LIGHT IT WILL ALSO STALL, AND TO RESTART THE ENGINE YOU HAVE TO STEP ON THE BRAKES, THEN A CAR BEHIND WILL ALMOST RUN INTO YOU.CREATING A DANGEROUS SITUATION.. AND I'VE TALKED TO A FEW PEOPLE WITH THE SAME MODEL VEHICLE AND THERE HAVING THE SAME STALLING PROBLEM..

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THE SADDLE BAG FELL OFF WHILE GOING DOWN THE HIGHWAY AND COLLIDED WITH THE MOTORCYCLE BEHIND IT CAUSING THE RIDER TO COME OFF AT 100 KM/HOUR. THIS IS NOT THE FIRST TIME THE SADDLE BAG HAS COME OFF. THE PREVIOUS TIME, IT WAS THE OTHER SIDE SO THE OWNER OF THIS MOTORCYCLE WAS EXTRA CAREFUL TO BE SURE THE BAGS WERE LATCHED PROPERLY PRIOR TO THE TRIP. IN OUR GROUP OF ABOUT 12 RIDERS, TWO OTHER MOTORCYCLISTS HAVE HAD HD SADDLEBAGS FALL OFF. WHEN I SPOKE TO OUR LOCAL DEALER, HE SAID HE'S HAD LOTS OF COMPLAINTS WHERE PEOPLE WANT TO HAVE THEIR SADDL…

Look up ODI 11219095 at NHTSA ↗

I GOT MY BIKE FROM WINTER STORAGE FROM THE HARLEY DEALERSHIP ON 5/8/14. THEY NEVER TOLD US THERE WAS ANY WORK DONE OVER THE WINTER. AFTER ASKING FOR A SERVICE MANAGER ON 6/2/14, TO SEE WHAT THEY HAD DONE TO THE BIKE DURING STORAGE WE RECEIVED THE PAPERWORK THAT SAID THERE WAS A LEAK IN THE STATOR ASSEMBLY AND PARTS WERE REPLACED UNDER WARRANTY. THE ROTORS ON THIS BRAND NEW BIKE (2954 MILES) WERE REPLACED AS THEY WERE STATED AS WARPED. THIS BIKE WAS IN THE SHOP FOR A REGULAR CHECK UP FOR OIL CHANGE ETC. 8/21/14, AND THEY ADJUSTED THE CLUTCH …

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SADDLEBAGS COME LOOSE FROM MOTORCYCLE WHILE RIDING AND FALL OFF WHILE GOING DOWN THE ROAD. VERY DANGEROUS FOR RIDERS AND OTHER TRAFFIC THAT MIGHT BE FOLLOWING OR COMING OTHER DIRECTION. FIRST ONE FELL OFF SAME DAY AS PURCHASED FROM HARLEY SHOP AND WE THOUGHT THEY DIDN'T PUT IT ON TIGHT AFTER WASHING BEFORE PICKING IT UP. SECOND ONE FELL OFF AFTER MAKING SURE IT WAS TIGHT ABOUT 3 WEEKS LATER. VERY DISAPPOINTED WITH THIS SINCE SADDLEBAGS ARE PART OF THE PURCHASE.

Look up ODI 11143039 at NHTSA ↗

WHILE SLOWING DOWN FOR A TURN TO THE LEFT, THE FRONT TIRE LOCKED AND SLID, RELEASED AND LOCKED AGAIN THROWING ME TO THE GROUND IN TURN I WOUND UP WITH 4 BROKEN RIBS, A BROKEN RIGHT HAND , INJURY TO MY RIGHT LEG AND ROAD RASH. 5000 DOLLARS PLUS TO MY BIKE AND HOSPITAL EMERGENCY ROOM NOT TO MENTION A LONG RECOVERY. I WAS ON A PAVED CITY ROAD GOING LESS THAN 30 MPH. I DO NOT KNOW EXACTLY WHAT CAUSED THIS TO HAPPEN

Look up ODI 11074728 at NHTSA ↗

TL* THE CONTACT OWNS A 2008 HARLEY DAVIDSON FLHR MOTORCYCLE. WHILE DRIVING APPROXIMATELY 35 MPH,THE MOTORCYCLE DECELERATED ABNORMALLY. THE FAILURE RECURRED WHEN DRIVING AT VARIOUS SPEEDS. THE MOTORCYCLE WAS TAKEN TO AN AUTHORIZED DEALER WHERE LUBRICANT WAS APPLIED TO THE ELECTRONIC THROTTLE CONNECTORS. THE MANUFACTURER WAS NOT NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 22,000. UPDATED 03/14/12 *BF

Look up ODI 10443180 at NHTSA ↗

SEVERAL TIMES OVER THE PAST 2 YEARS I HAVE LOST ABILITY TO CONTROL MY THROTTLE. THROTTLE POSITION CLOSES AND DOES NOT ACCEPT INPUTS FROM THE ACCELERATOR. SEVERAL TIMES WHILE TRAVELING ON THE EXPRESSWAY THE THROTTLE HAS SHUT AND THE MOTORCYCLE WENT INTO 'LIMP HOME' MODE. THIS WILL ONLY ALLOW A SPEED OF APPROXIMATELY 10-15MPH (DANGEROUS WHILE TRAVELING AT HIGH RATES OF SPEED). THE CONCERN IS WELL KNOW BY THE HARLEY DAVIDSON COMPANY. THEY HAVE EVEN ISSUED A TECHNICAL TIP BULLETIN (#TT418A) ON THE SUBJECT. HOWEVER, NO VOLUNTARY OR REQUIRED SAFETY …

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AT AN INTERSECTION AFTER LIGHT CHANGED, ENGINE LOST ALL POWER AS I TRIED TO MAKE MY TURN. HAD TO IDLE AT ABOUT 5 MPH INTO A GAS STATION PARKING LOT WHILE TRAFFIC WENT AROUND ME. DIAGNOSIS WAS A BAD THROTTLE BODY MODULE. THIS IS MY PRIMARY MEANS OF TRANSPORTATION AND THE DEALER IS STILL TRYING TO GET THE REPLACEMENT PART FOR A WEEK NOW. FROM WHAT I'VE READ THIS IS A KNOW ISSUE WITH H-D TOURING MODELS GOING BACK TO 2008 AND MAY OCCUR AGAIN IN THE FUTURE. *TR

Look up ODI 10627264 at NHTSA ↗